Lithium-ion secondary battery, negative electrode for lithium-ion secondary battery, battery pack, electric vehicle, power storage system, electric tool, and electronic device

ABSTRACT

A lithium-ion secondary battery includes a positive electrode, a negative electrode containing an active material, and an electrolytic solution, in which the active material contains, as constituent elements, Si, O, and at least one element Ml selected from Li, C, Mg, Al, Ca, Ti, Cr, Mn, Fe, Co, Ni, Cu, Ge, Zr, Mo, Ag, Sn, Ba, W, Ta, Na, and K, and the atomic ratio x (O/Si) of O to Si is 0.5≦x≦1.8.

CROSS REFERENCES TO RELATED APPLICATIONS

The present application claims priority to Japanese Priority Patent Application JP 2011-141004 filed in the Japan Patent Office on Jun. 24, 2011, the entire content of which is hereby incorporated by reference.

BACKGROUND

The present application relates to a negative electrode for a lithium-ion secondary battery, the negative electrode containing a negative-electrode active material capable of occluding and releasing lithium ions, a lithium-ion secondary battery including the negative electrode, a battery pack, an electric vehicle, a power storage system, an electric tool, and an electronic device, which include the secondary battery.

In recent years, electronic devices typified by, for example, cellular phones and personal digital assistants (PDAs) have been widely used. Further size and weight reduction and longer life of electronic devices have been strongly demanded. Thus, there have been advances in the development of batteries serving as power sources, in particular, small and lightweight secondary batteries having a high energy density. Recently, various applications of secondary batteries to, for example, battery packs, electric vehicles, such as electric automobiles, power storage systems, such as power servers for household use, and electric tools, such as electric drills, as well as electronic devices described above have been studied.

Secondary batteries using various charge-discharge principles have been reported. In particular, lithium-ion secondary batteries that utilize the occlusion and release of lithium ions hold great promise because they have higher energy densities than lead-acid batteries, nickel-cadmium batteries, and other batteries.

A lithium-ion secondary battery includes a positive electrode, a negative electrode, and an electrolytic solution. The negative electrode contains a negative-electrode active material capable of occluding and releasing lithium ions. As the negative-electrode active material, a carbon material, such as graphite, is widely used. Recently, secondary batteries have been required to have higher battery capacities. Thus, the use of Si has been studied. The theoretical capacity of Si (4199 mAh/g) is much higher than the theoretical capacity of graphite (372 mAh/g), so the battery capacity should be significantly improved.

However, the use of Si as a negative-electrode active material causes extreme expansion and contraction of the negative-electrode active material during charge and discharge, so that the negative-electrode active material is liable to be cracked mainly in the vicinity of its surface. When the negative-electrode active material is cracked, a high-reactive newly-formed surface (an active surface) is formed, thereby increasing the surface area (reactive area) of the negative-electrode active material. As a result, the decomposition reaction of an electrolytic solution occurs on the newly-formed surface. The electrolytic solution is consumed to form a coating film derived from the electrolytic solution on the newly-formed surface. Thus, battery characteristics, such as cycle characteristics, are liable to decrease.

Thus, in order to improve battery characteristics, such as cycle characteristics, various configurations of the lithium-ion secondary batteries have been studied.

Specifically, to improve cycle characteristics and safety, Si and amorphous SiO₂ are simultaneously deposited by a sputtering method (for example, see Japanese Unexamined Patent Application Publication No. 2001-185127). To obtain excellent battery capacity and safety performance, electron-conductive material layers (carbon material) are arranged on surfaces of SiO_(x) particles (for example, see Japanese Unexamined Patent Application Publication No. 2002-042806). To improve high rate charge-discharge characteristics and cycle characteristics, a negative-electrode active material layer containing Si and O is formed in such a manner that the oxygen content is increased with decreasing distance from a negative-electrode collector (for example, see Japanese Unexamined Patent Application Publication No. 2006-164954). To improve cycle characteristics, a negative-electrode active material layer containing Si and O is formed in such a manner that the average oxygen content in the whole negative-electrode active material layer is 40 atomic percent or less and that the average oxygen content is increased with decreasing distance from a negative-electrode collector (for example, see Japanese Unexamined Patent Application Publication No. 2006-114454). In this case, a difference in average oxygen content between a portion near the negative-electrode collector and a portion remote from the negative-electrode collector is in the range of 4 atomic percent to 30 atomic percent.

To improve initial charge-discharge characteristics and the like, a nano-composite including a Si phase, SiO₂, and metal oxide M_(y)O is used (for example, see Japanese Unexamined Patent Application Publication No. 2009-070825). To improve cycle characteristics, powdered SiO_(x) (0.8≦x≦1.5, particle size range: 1 μm to 50 μm) and a carbonaceous material are mixed and fired at 800° C. to 1600° C. for 3 hours to 12 hours (for example, see Japanese Unexamined Patent Application Publication No. 2008-282819). To shorten an initial charge time, a negative-electrode active material expressed as Li_(a)SiO_(x) (0.5≦a-x≦1.1 and 0.2≦x≦1.2) is used (for example, see International Publication No. WO2007/010922). In this case, Li is deposited by evaporation on an active material precursor containing Si and O. To improve charge-discharge cycle characteristics, the composition of SiO_(x) is controlled in such a manner that the molar ratio of the O content to the Si content of a negative-electrode active material is in the range of 0.1 to 1.2 and that a difference between the maximum value and the minimum value of the molar ratio of the O content to the Si content in the vicinity of a boundary between the negative-electrode active material and a current collector is 0.4 or less (for example, see Japanese Unexamined Patent Application Publication No. 2008-251369). To improve load characteristics, a Li-containing porous metal oxide (Li_(x)SiO: 2.1≦x≦4) is used (for example, Japanese Unexamined Patent Application Publication No. 2008-177346).

To improve charge-discharge cycle characteristics, a hydrophobic layer of a silane compound, a siloxane compound, or the like is formed on a thin film containing Si (for example, see Japanese Unexamined Patent Application Publication No. 2007-234255). To improve cycle characteristics, a conductive powder in which surfaces of SiO_(x) (0.5≦x<1.6) particles are covered with graphite coating films is used (for example, see Japanese Unexamined Patent Application Publication No. 2009-212074). In this case, on Raman spectroscopy analysis, each graphite coating film develops broad peaks at 1330 cm⁻¹ and 1580 cm⁻¹ Raman shift, and an intensity ratio I₁₃₃₀/I₁₅₈₀ is 1.5<I₁₃₃₀/I₁₅₈₀<3. To improve a battery capacity and cycle characteristics, a powder including 1% by mass to 30% by mass of particles is used, the particles each having a structure in which Si microcrystals (crystal size: 1 nm to 500 nm) are dispersed in SiO₂ (for example, see Japanese Unexamined Patent Application Publication No. 2009-205950). In this case, in a particle size distribution by a laser diffraction/scattering type particle size distribution measurement method, the 90% accumulated diameter (D90) of the power is 50 μm or less, and the particle diameters of the particles are less than 2 μm. To improve cycle characteristics, SiO_(x) (0.3≦x≦1.6) is used, and an electrode unit is pressurized at a pressure of 3 kgf/cm² or more during charge and discharge (for example, see Japanese Unexamined Patent Application Publication No. 2009-076373). To improve overcharge characteristics, over-discharge characteristics, and the like, an oxide of silicon with a silicon-oxygen atomic ratio of 1:y (0<y<2) is used (for example, see Japanese Patent No. 2997741).

Furthermore, in order to electrochemically accumulate or release a large amount of lithium ions, an amorphous metal oxide is provided on surfaces of primary particles of Si or the like (for example, see Japanese Unexamined Patent Application Publication No. 2009-164104). The Gibbs free energy when the metal oxide is formed by oxidation of a metal is lower than the Gibbs free energy when Si or the like is oxidized. To achieve a high capacity, high efficiency, a high operating voltage, and long lifetime, it is reported that a negative-electrode material in which the oxidation numbers of Si atoms satisfy predetermined requirements is used (for example, see Japanese Unexamined Patent Application Publication No. 2005-183264). The negative-electrode material contains Si with an oxidation number of zero, a Si compound having a Si atom with an oxidation number of +4, and a lower oxide of Si having a silicon atoms with oxidation numbers of more than zero and less than +4.

SUMMARY

Electronic devices and so force have higher performance and more functions and are more frequently used. Thus, lithium-ion secondary batteries tend to be frequently charged and discharged. Hence, lithium-ion secondary batteries are required to have further improved battery characteristics.

It is desirable to provide a negative electrode for a lithium-ion secondary battery, the negative electrode providing excellent battery characteristics, a lithium-ion secondary battery, a battery pack, an electric vehicle, a power storage system, an electric tool, and an electronic device.

A negative electrode for a lithium-ion secondary battery according to an embodiment of the present application includes an active material. The active material contains, as constituent elements, Si, O, and at least one element Ml selected from Li, C, Mg, Al, Ca, Ti, Cr, Mn, Fe, Co, Ni, Cu, Ge, Zr, Mo, Ag, Sn, Ba, W, Ta, Na, and K. The atomic ratio x (O/Si) of O to Si is 0.5≦x≦1.8. A lithium-ion secondary battery according to an embodiment of the present application includes a positive electrode, a negative electrode, and an electrolytic solution, in which the negative electrode contains the same active material as the foregoing negative electrode for a lithium-ion secondary battery. A battery pack, an electric vehicle, a power storage system, an electric tool, or an electronic device according to an embodiment of the present application includes the lithium-ion secondary battery according to an embodiment of the present application.

In the negative electrode for a lithium-ion secondary battery or the lithium-ion secondary battery according to an embodiment of the present application, the active material of the negative electrode contains, as constituent elements, Si, O, and element Ml, such as Li, and the atomic ratio x of O to Si is 0.5≦x≦1.8. It is thus possible to obtain excellent battery characteristics. Furthermore, for the battery pack, the electric vehicle, the power storage system, the electric tool, or the electronic device according to an embodiment of the present application, it is possible to obtain the same effect.

Additional features and advantages are described herein, and will be apparent from the following Detailed Description and the figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a sectional view illustrating a structure of a negative electrode for a lithium-ion secondary battery according to an embodiment of the present application;

FIG. 2 is a sectional view illustrating a structure of a lithium-ion secondary battery (prismatic type) according to an embodiment of the present application;

FIG. 3 is a sectional view taken along line III-III in FIG. 2 that illustrates the lithium-ion secondary battery;

FIG. 4 is a schematic plan view illustrating structures of a positive electrode and a negative electrode illustrated in FIG. 3;

FIG. 5 is a sectional view illustrating a structure of a lithium-ion secondary battery (cylindrical type) according to an embodiment of the present application;

FIG. 6 is a partially enlarged sectional view of a spirally wound electrode illustrated in FIG. 5;

FIG. 7 is an exploded perspective view illustrating a structure of a lithium-ion secondary battery (laminated-film type) according to an embodiment of the present application;

FIG. 8 is an enlarged cross-sectional view taken along line VIII-VIII in FIG. 7 that illustrates a spirally wound electrode;

FIG. 9 is a block diagram illustrating the configuration of an application example (battery pack) of a lithium-ion secondary battery;

FIG. 10 is a block diagram illustrating the configuration of an application example (electric vehicle) of a lithium-ion secondary battery;

FIG. 11 is a block diagram illustrating the configuration of an application example (power storage system) of a lithium-ion secondary battery; and

FIG. 12 is a block diagram illustrating the configuration of an application example (electric tool) of a lithium-ion secondary battery.

DETAILED DESCRIPTION

Embodiments of the present application will be described in detail below with reference to the attached drawings. Descriptions are made in the order listed below:

1. negative electrode for lithium-ion secondary battery,

2. lithium-ion secondary battery,

2-1. prismatic type,

2-2. cylindrical type,

2-3. laminated-film type,

3. application of lithium-ion secondary battery,

3-1. battery pack,

3-2. electric vehicle,

3-3. power storage system, and

3-4. electric tool.

1. Negative Electrode for Lithium-Ion Secondary Battery

FIG. 1 illustrates a sectional structure of a negative electrode for a lithium-ion secondary battery (hereinafter, referred to simply as a “negative electrode”) according to an embodiment of the present application.

Overall Structure of Negative Electrode

The negative electrode includes, for example, as illustrated in FIG. 1, negative-electrode active material layers 2 on a negative-electrode collector 1. For this negative electrode, the negative-electrode active material layers 2 may be arranged on both surfaces of the negative-electrode collector 1. Alternatively, one negative-electrode active material layer may be arranged on only one surface of the collector. Furthermore, the negative-electrode collector 1 may not be arranged.

Negative-Electrode Collector

The negative-electrode collector 1 is composed of, for example, a conductive material having excellent electrochemical stability, electrical conductivity, and mechanical strength. Examples of the conductive material include Cu, Ni, and stainless steel. In particular, a material which does not form an intermetallic compound with Li and which can be alloyed with a material constituting the negative-electrode active material layers 2 is preferred.

The negative-electrode collector 1 preferably contains, as constituent elements, C and S. The reason for this is that the physical strength of the negative-electrode collector 1 is improved, so that the negative-electrode collector 1 is less likely to be deformed even if the negative-electrode active material layers 2 expand and contract during charge and discharge. An example of the negative-electrode collector 1 is metal foil doped with C and S. The C content and the S content are not particularly limited and are each preferably 100 ppm or less because a higher effect is obtained.

The negative-electrode collector 1 may have a roughened surface or may not have a roughened surface. An example of the negative-electrode collector 1 having an unroughened surface is rolled metal foil. An example of the negative-electrode collector 1 having a roughened surface is metal foil that has been subjected to electrolytic treatment or sandblasting. The electrolytic treatment is a method in which fine particles are formed on a surface of metal foil or the like in an electrolytic bath by an electrolytic process to produce irregularities. Metal foil produced by the electrolytic process is commonly referred to as electrolytic foil (e.g., electrolytic Cu foil).

The negative-electrode collector 1 preferably has a roughened surface because the adhesion of the negative-electrode active material layers 2 to the negative-electrode collector 1 is improved by an anchor effect. The surface roughness (e.g., ten-point height of irregularities Rz) of the negative-electrode collector 1 is not particularly limited and is preferably maximized in order to improve the adhesion of the negative-electrode active material layers 2 by the anchor effect. However, an excessively high surface roughness may result in a reduction in the adhesion of the negative-electrode active material layers 2.

Negative-Electrode Active Material Layer

Each of the negative-electrode active material layers 2 contains a plurality of particles of a negative-electrode active material capable of occluding and releasing lithium ions. If necessary, each of the negative-electrode active material layers 2 may further contain an additional material, for example, a negative-electrode binder or a negative-electrode conductive agent.

The negative-electrode active material contains, as constituent elements, Si, O, and element Ml that can form an alloy with Si. Element Ml is at least one selected from Li, C, Mg, Al, Ca, Ti, Cr, Mn, Fe, Co, Ni, Cu, Ge, Zr, Mo, Ag, Sn, Ba, W, Ta, Na, and K. The atomic ratio x of O to Si, i.e., O/Si, is 0.5≦x≦1.8.

The reason the atomic ratio x is within the range described above is that the degradation of the negative-electrode active material is suppressed when charge and discharge are repeated compared with the case where the atomic ratio x is outside the range (i.e., x<0.5, or x>1.8). In this case, the entry and exit of lithium ions from the negative-electrode active material are ensured.

The reason the negative-electrode active material contains Ml is that when the atomic ratio x is within the range described above, a compound (Si-Ml-O) of Si, O, and Ml is easily formed in the negative-electrode active material. That is, usually, SiO_(x) improves cycle characteristics but is liable to cause a reduction in battery capacity due to an increase in irreversible capacity. The formation of Si-Ml-O reduces the irreversible capacity. This results in a reduction in irreversible capacity and a reduction in the electrical resistance of the negative-electrode active material.

In the negative-electrode active material, at least one of the atoms of Ml may form Si-Ml-O. Also in this case, the foregoing advantages are provided. The remaining Ml may be present in a free elemental form, may form an alloy with Si, or may be combined with O to form a compound. Alternatively, two or more thereof may be present.

More particularly, in the case where at least one of the atoms of Si is bonded to at least one of the atoms of O, the bonding states (valence states) of Si atoms bonded to O atoms include zero valence (Si⁰⁺), monovalence (Si¹⁺), divalence (Si²⁺), trivalence (Si³⁺), and tetravalence (Si⁴⁺). The presence or absence of Si atoms in these bonding states and their proportions (atomic ratios) can be determined by analysis of the negative-electrode active material by, for example, X-ray photoelectron spectroscopy (XPS). Note that in the case where the outermost layer of the negative-electrode active material is unintentionally oxidized (SiO₂ is formed), the analysis is preferably performed after SiO₂ is removed by dissolution with HF or the like.

In the case where Si-Ml-O is formed in the negative-electrode active material, in the zero-valent to tetra-valent bonding states, the proportion of the tetravalent silicon which is liable to lead to irreversible capacity during charge and discharge and which has high resistance is relatively reduced. The proportion of the zero-valent silicon which has the tendency opposite to that of the tetravalent silicon is relatively increased. This is less likely to cause irreversible capacity even if the negative-electrode active material is SiO_(x).

Accordingly, the proportions of the bonding states of Si atoms bonded to O atoms preferably satisfy the relationship Si⁴⁺<Si⁰⁺+Si¹⁺+Si²⁺+Si⁺. This is because a low proportion of tetravalent silicon results in a reduction in irreversible capacity. Furthermore, the proportions preferably satisfy the relationships Si⁴⁺>Si⁰⁺, Si⁴⁺≧Si¹⁺, and Si⁴⁺≧Si²⁺. This is because an excessively low proportion of tetravalent silicon disadvantageously causes a reduction cycle characteristics. Moreover, the proportion of Si¹⁺ is preferably less than 10 atomic percent. This is because an excessively high proportion of monovalent silicon results in a reduction in cycle characteristics.

In particular, Ml is preferably at least one element selected from C, Al, Fe, Co, Ni, and Sn. The atomic ratio x is preferably 0.7≦x≦1.3 and more preferably x=1.2. This is because a higher effect is provided.

The ratio of Ml to Si and O, i.e., Ml/(Si+O), is not particularly limited and is preferably 50 atomic percent or less and more preferably 20 atomic percent or less. This is because the advantages described above are obtained while suppressing a reduction in battery capacity due to the presence of Ml.

The negative-electrode active material may be crystalline, noncrystalline (amorphous), or may have low crystallinity. In particular, the negative-electrode active material is preferably noncrystalline or preferably has low crystallinity. The reason for this is as follows: lithium ions are easily diffused compared with the case where the negative-electrode active material is crystalline (high crystallinity), so that lithium ions are easily and smoothly occluded and released. Furthermore, the negative-electrode active material is preferably noncrystalline. This is because the negative-electrode active material is less likely to trap lithium ions, so that the entry and exit of lithium ions are less likely to be inhibited.

The term “low crystallinity” indicates that the negative-electrode active material includes a noncrystalline region and a crystalline region, the material being different from a “noncrystalline” material including a noncrystalline region alone. To identify whether the negative-electrode active material has low crystallinity or not, for example, the negative-electrode active material may be observed with a high-angle annular dark-field scanning transmission electron microscopy (HAADF STEM). If a TEM photograph reveals that a noncrystalline region and a crystalline region are both present, the negative-electrode active material has low crystallinity. In the case where a noncrystalline region and a crystalline region are both present, the crystalline region is observed as a region (crystal grain) having a granular contour. A striped pattern (crystal lattice pattern) attributed to the crystallinity is observed inside the crystal grain. It is thus possible to distinguish the crystal grain from the noncrystalline region.

The negative-electrode active material may have a single-layer structure or a multilayer structure. In particular, the negative-electrode active material preferably has a multilayer structure. This is because the negative-electrode active material is less likely to be broken even if the negative-electrode active material expands and contracts during charge and discharge. More particularly, for the negative-electrode active material having a single-layer structure, internal stress thereof is not easily relaxed, depending on its thickness. Thus, the negative-electrode active material can be broken (e.g., fracture or separation) due to expansion and contraction during charge and discharge. In contrast, for the negative-electrode active material having a multilayer structure, a minute gap between layers functions as a gap that relaxes stress. Thus, the internal stress is relaxed, so that the negative-electrode active material is not easily broken.

For the negative-electrode active material having the single-layer structure, Si, O, and Ml are contained in the single layer. For the negative-electrode active material having the multilayer structure, layers containing Si, O, and Ml may be stacked. Alternatively, a layer containing Si and O and a layer containing Si, O, and Ml may be stacked. Furthermore, these layers may be mixed. Also in this case, the same effect is provided. Of course, any stacking order of the layers may be used in the multilayer structure.

In particular, the negative-electrode active material may contain Li serving as a constituent element in an uncharged state because the electrical resistance of the negative-electrode active material is reduced. The Li is already contained in the negative-electrode active material in the uncharged state and thus is different from Li that is released from the positive electrode during charge and then occluded in the negative electrode. That is, the Li is incorporated in the negative-electrode active material in advance.

Also in this case, Li may be present alone (elemental state) without combination with Si or O. Alternatively, Li may be combined with Si or O to form a compound or an alloy. Preferably, at least one of the atoms of Li is combined with at least one of Si or O to form a compound. Accordingly, the negative-electrode active material preferably contains Si—Li—O because irreversible capacity is reduced.

To check the fact that the negative-electrode active material contains Si, O, and Ml, the negative-electrode active material may be analyzed by, for example, X-ray photoelectron spectroscopy (XPS) or energy-dispersive X-ray analysis (EDX) in addition to the SEM observation described above.

In this case, for example, the composition (atomic ratio x) of the negative-electrode active material can be identified by measuring, for example, the degrees of oxidation of the negative-electrode active material. In the case where the degree of oxidation is measured, for example, the negative-electrode active material is quantified by a combustion method to calculate the total amount of Si and the total amount of O. Thus, the amount of Si and the amount of O in the negative-electrode active material are determined thus determining the degrees of oxidation.

The median diameter of the negative-electrode active material is not particularly limited. In particular, the negative-electrode active material preferably has a median diameter of 0.3 μm to 20 μm because the negative-electrode active material easily occludes and releases lithium ions during charge and discharge and because the negative-electrode active material is not easily broken. More particularly, a median diameter of less than 0.3 μm can facilitate expansion and contraction during charge and discharge because of an excessively large total surface area of the negative-electrode active material. A median diameter exceeding 20 μm is liable to lead to a break of the negative-electrode active material during charge and discharge.

In particular, the negative electrode preferably includes a conductive layer on a surface of the negative-electrode active material. The conductive layer is arranged on at least part of the surface of the negative-electrode active material and has a lower electrical resistance than that of the negative-electrode active material. In this case, the negative-electrode active material does not easily come into contact with an electrolytic solution, thus inhibiting the decomposition reaction of the electrolytic solution. Furthermore, the electrical resistance of the negative-electrode active material is further reduced. The conductive layer contains, for example, one or two or more of carbon materials, metal materials, and inorganic compounds. An example of carbon materials is graphite. Examples of metal materials include Fe, Cu, and Al. An example of inorganic compounds is SiO₂. Among these materials, carbon materials or metal materials are preferred. Carbon materials are more preferred. This is because the electrical resistance of the negative-electrode active material is further reduced.

The conductive layer may have any average coverage and any average thickness. For example, the average thickness is calculated by the following procedure. One particle of the negative-electrode active material is observed with a scanning electron microscope (SEM). To measure the thickness of the conductive layer, the observation is preferably performed at a magnification such that the boundary between the negative-electrode active material and the conductive layer can be visually identified (determined). Subsequently, thicknesses of the conductive layer are measured at 10 random positions. Then the average value of the thicknesses (average thickness of one particle) is calculated. In this case, the measurement positions are preferably set in such a manner that the measurement positions are not localized at a specific site but are widely distributed to the extent possible. Next, the foregoing calculation of the average value is repeated until the total number of particles observed with the SEM reaches 100. Finally, the average value (average value of the average thicknesses) of the calculated average thicknesses (corresponding to the respective particles) of 100 particles of the negative-electrode active material is calculated and defined as the average thickness.

For example, the average coverage is calculated by the following procedure. As with the case where the average thickness is calculated, one particle of the negative-electrode active material is observed with a scanning electron microscope (SEM). The observation is preferably performed at a magnification such that in the negative-electrode active material, a portion that is covered with the conductive layer and a portion that is not covered with the conductive layer can be visually distinguished. With respect to the outer edge (contour) of the negative-electrode active material, the length of a portion that is covered with the conductive layer and the length of a portion that is not covered with the conductive layer are measured. Then the following calculation is performed: coverage (coverage for one particle: %)=(length of portion covered with conductive layer/length of outer edge of negative-electrode active material)×100. Next, the foregoing calculation of the coverage is repeated until the total number of particles observed with the SEM reaches 100. Finally, the average value of the calculated coverage values (corresponding to the respective particles) of 100 particles of the negative-electrode active material is calculated and defined as the average coverage.

The negative-electrode binder contains, for example, one or two or more of synthetic rubber and polymeric materials. Examples of synthetic rubber include styrene-butadiene-based rubber, fluorocarbon rubber, and ethylene-propylene-diene. Examples of polymeric materials include polyvinylidene fluoride, polyimide, polyamide, polyamide-imide, polyacrylic acid, lithium polyacrylate, sodium polyacrylate, polymaleic acid, and copolymers thereof. Further examples of polymeric materials include carboxymethyl cellulose, styrene-butadiene rubber, and polyvinyl alcohol.

The negative-electrode conductive agent contains, for example, one or two or more of carbon materials, such as graphite, carbon black, acetylene black, and Ketjenblack. The negative-electrode conductive agent may also be a conductive material, for example, a metal material or a conductive polymer.

The negative-electrode active material layers 2 may contain another negative-electrode active material in addition to the negative-electrode active material described above.

An example of another negative-electrode active material is a carbon material. This is because the electrical resistance of the negative-electrode active material layers 2 is reduced and because the negative-electrode active material layers 2 are less likely to expand and contract during charge and discharge. Examples of the carbon material include graphitizable carbon, non-graphitizable carbon in which the interplanar spacing of the (002) planes is 0.37 nm or more, and graphite in which the interplanar spacing of the (002) planes is 0.34 nm or less. Specific examples thereof include pyrolytic carbon, coke, glassy carbon fibers, a burned organic polymeric compound, activated carbon, and carbon black. Examples of coke include pitch coke, needle coke, and petroleum coke. The burned organic polymeric compound refers to a material formed by burning a phenolic resin or a furan resin at an appropriate temperature into carbon. The carbon material may have any shape selected from fibrous shapes, spherical shapes, granular shapes, and flaky shapes. The carbon material content of the negative-electrode active material layers 2 is not particularly limited and is preferably 60% by weight or less and more preferably 10% by weight to 60% by weight.

Furthermore, another negative-electrode active material may be a metal oxide or a polymeric compound. Examples of the metal oxide include iron oxide, ruthenium oxide, and molybdenum oxide. Examples of the polymeric compound include polyacetylene, polyaniline, and polypyrrole.

The negative-electrode active material layers 2 are formed by, for example, an application method, a firing method (a sintering method), or a combination of two or more thereof. The application method refers to a method in which, for example, a negative-electrode active material is mixed with a negative-electrode binder, the resulting mixture is dispersed in an organic solvent, and application is performed. The firing method refers to a method in which, for example, after application is performed in the same way as the application method, heat treatment is performed at a temperature higher than the melting point of the negative-electrode binder or the like. As the firing method, a method of the related art may be employed. Examples thereof include an atmosphere firing method, a reactive firing method, and a hot-press firing method.

Production Method of Negative Electrode

A negative electrode is produced by, for example, a procedure described below.

First, a material to be formed into the negative-electrode active material is deposited on a surface of a substrate by a vapor deposition method, for example, an evaporation method or a sputtering method. In this case, as raw materials, a material containing Si, O, and Ml may be used. Alternatively, a material containing Si and O (e.g., SiO_(x)) and elemental Ml may be used. For the latter, the proportion of Ml can be adjusted in response to the deposition rate of the Ml. In the case where the vapor deposition method is employed, the negative-electrode active material tends to be noncrystalline. In this case, the material may be deposited while being heated by, for example, induction heating, resistance heating, or electron-beam (EB) heating. Alternatively, after the deposition, the material may be heated. The degree of the low crystallinity is controlled, depending on, for example, heating conditions, such as temperature and time.

In particular, in the case where the vapor deposition method is employed, Si-Ml-O is easily formed in the resulting film by heating not only the material constituting the negative-electrode active material but also a substrate used for the deposition. The temperature of the substrate is preferably in the range of, for example, 25° C. to 800° C. At a temperature exceeding 800° C., SiO_(x) and so forth are re-evaporated. When the material constituting the negative-electrode active material is deposited, the atomic ratio x can be adjusted by adjusting the flow rates of O₂ gas, H₂ gas, and so forth introduced into a chamber. Furthermore, the proportions of the bonding states of Si atoms bonded to O atoms can be controlled by adjusting the substrate temperature or the temperature of the material constituting the negative-electrode active material. Next, the deposited film is pulverized to form the negative-electrode active material. In this case, the pulverization may be repeated until a desired particle size (e.g., median diameter) of the negative-electrode active material is obtained.

After the formation of the negative-electrode active material, the conductive layer may be formed on a surface of the negative-electrode active material by, for example, a vapor deposition method, such as an evaporation method, a sputtering method, or a chemical vapor deposition (CVD) method, or a wet coating method.

In the case where the evaporation method is employed, for example, vapor is allowed to impinge directly on the surface of the negative-electrode active material to form a conductive layer. In the case where the sputtering method is employed, for example, a conductive layer is formed by a powder sputtering method while Ar gas is introduced. In the case where the CVD method is employed, for example, a gas formed by subliming a metal chloride and a mixed gas of H₂, N₂, and so forth are mixed in such a manner that the mole fraction of the metal chloride is in the range of 0.03 to 0.3, and then the resulting gas is heated to 1000° C. or higher to form a conductive portion on the surface of the covering portion, thereby forming a conductive layer. In the case where the wet coating method is employed, for example, an alkali solution is added to a slurry containing the negative-electrode active material while a metal-containing solution is added to the slurry to form a metal hydroxide. Then reduction treatment with hydrogen is 450° C. performed at 450° C. to form a conductive layer on the surface of the negative-electrode active material. In the case where a carbon material is used as a material constituting the conductive layer, the negative-electrode active material is placed in a chamber. An organic gas is introduced into the chamber. Heat treatment is performed at 10,000 Pa and 1000° C. or higher for 5 hours to form a conductive layer on the surface of the negative-electrode active material. The organic gas is not particularly limited as long as it is thermally decomposed to form carbon. Examples of the organic gas include methane, ethane, ethylene, acetylene, and propane.

Next, the negative-electrode active material and other materials, such as the negative-electrode binder, are mixed to form a negative-electrode mixture. The resulting negative-electrode mixture is dissolved in a solvent, such as an organic solvent, to form a slurry containing the negative-electrode mixture. Finally, the slurry containing the negative-electrode mixture is applied to the surface of the negative-electrode collector 1 and dried to form the negative-electrode active material layers 2. If necessary, the negative-electrode active material layers 2 may be subjected to compression forming and heated (fired).

Function and Effect of Embodiment

In the negative electrode, the negative-electrode active material contains, as constituent elements, Si, O, element M, such as Li. The atomic ratio y of O to Si is 0.5≦x≦1.8. Thus, the negative-electrode active material easily and smoothly occludes and releases lithium ions. Furthermore, Si-M-O is easily formed in the negative-electrode active material, thereby inhibiting the occurrence of irreversible capacity and reducing the electrical resistance of the negative-electrode active material. Accordingly, the negative electrode contributes to improvement in the performance of a lithium-ion secondary battery including the negative electrode. Specifically, the negative electrode contributes to improvement in cycle characteristics, initial charge-discharge characteristics, load characteristics, and so forth.

In particular, in the case where the ratio of Ml to Si and O is preferably 50 atomic percent or less and more preferably 20 atomic percent or less, a higher effect can be provided. In the case where the proportions of the bonding states of Si atoms bonded to O atoms satisfy the relationships Si⁴⁺<Si⁰⁺+Si¹⁺+Si²⁺+Si³⁺, Si⁴⁺>Si⁰⁺, Si⁴⁺≧Si¹⁺, and Si⁴⁺≧Si²⁺, and where the proportion of Si¹⁺ is less than 10 atomic percent, a higher effect can be provided. Moreover, the negative-electrode active material has a multilayer structure, a higher effect can be provided.

In the case where the negative-electrode active material contains Li as a constituent element in an uncharged state and where the negative-electrode active material contains Si—Li—O, a higher effect can be provided. Furthermore, in the case where the conductive layer having a lower electrical resistance than the negative-electrode active material is formed on the surface of the negative-electrode active material, a higher effect can be provided.

2. Lithium-Ion Secondary Battery

A lithium-ion secondary battery including the negative electrode for a lithium-ion secondary battery (hereinafter, referred to simply as “secondary battery”) will be described below.

2-1. Prismatic Type

FIGS. 2 and 3 are sectional views illustrating a structure of a prismatic lithium-ion secondary battery. FIG. 3 is a sectional view taken along line III-III in FIG. 2. FIG. 4 is a schematic plan view illustrating structures of a positive electrode 21 and a negative electrode 22 illustrated in FIG. 3.

Entire Structure of Secondary Battery

The prismatic secondary battery mainly includes a battery element 20 in a battery can 11. The battery element 20 is formed of a spirally wound laminate in which the positive electrode 21 and the negative electrode 22 are stacked with a separator 23 provided therebetween and spirally wound, the battery element 20 having a flattened shape in response to the shape of the battery can 11.

The battery can 11 is, for example, a prismatic package member. As illustrated in FIG. 3, the prismatic package member has a rectangular or substantially rectangular (partially curved) shape in longitudinal section. The prismatic package member can be used to not only a prismatic battery with a rectangular shape but also a prismatic battery with an oval shape. In other words, the prismatic package member is a vessel-shaped member having a rectangular closed end or an oval closed end and having an opening portion with a rectangular shape or a substantially rectangular (oval) shape formed by connecting arcs with straight lines. FIG. 4 illustrates the battery can 11 having a rectangular section.

The battery can 11 is composed of a conductive material, for example, iron, aluminum, or an alloy thereof. The battery can 11 may function as an electrode terminal. Among these materials, Fe, which is harder than Al, is preferred in order to prevent swelling of the battery can 11 during charge and discharge with use of the hardness (resistance to deformation) of the battery can 11. In the case where the battery can 11 is composed of Fe, the surface of the battery can 11 may be plated with Ni or the like.

The battery can 11 has a hollow structure having an open end portion and a closed end portion. The battery can 11 is sealed with an insulating plate 12 and a battery cover 13 attached to the open end portion. The insulating plate 12 is arranged between the battery element 20 and the battery cover 13. The insulating plate 12 is composed of an insulating material, such as polypropylene. The battery cover 13 is composed of, for example, a material the same as that of the battery can 11. Similarly to the battery can 11, the battery cover 13 may function as an electrode terminal.

A terminal plate 14 serving as a positive-electrode terminal is arranged outside the battery cover 13. The terminal plate 14 is electrically insulated from the battery cover 13 with an insulating case 16 provided therebetween. The insulating case 16 is composed of an insulating material, such as polybutylene terephthalate. A through hole is arranged in the substantially middle of the battery cover 13. A positive-electrode pin 15 is interposed in the through hole so as to be electrically connected to the terminal plate 14 and so as to be electrically insulated from the battery cover 13 with a gasket 17. The gasket 17 is composed of, for example, an insulating material. The surface of the gasket 17 is coated with asphalt.

A cleavage valve 18 and an injection hole 19 are arranged at the outer edge of the battery cover 13. The cleavage valve 18 is electrically connected to the battery cover 13. If the internal pressure of the battery is increased to a predetermined value or higher by an internal short-circuit or externally applied heat, the cleavage valve 18 is separated from the battery cover 13 to release the internal pressure. The injection hole 19 is capped with a sealing member 19A formed of, for example, a stainless-steel ball.

A positive-electrode lead 24 composed of a conductive material, such as Al, is attached to an end portion (for example, an inner end portion) of the positive electrode 21. A negative-electrode lead 25 composed of a conductive material, such as Ni, is attached to an end portion (for example, an outer end portion) of the negative electrode 22. The positive-electrode lead 24 is welded to an end of the positive-electrode pin 15 and is electrically connected to the terminal plate 14. The negative-electrode lead 25 is welded and electrically connected to the battery can 11.

Positive Electrode

For example, the positive electrode 21 includes a positive-electrode active material layer 21B provided on each surface of a positive-electrode collector 21A. Alternatively, the positive-electrode active material layer 21B may be arranged on only one surface of the positive-electrode collector 21A.

The positive-electrode collector 21A is composed of a conductive material, e.g., Al, Ni, or stainless steel.

Each of the positive-electrode active material layers 21B contains one or two or more positive-electrode materials which serve as positive-electrode active materials and which are capable of occluding and releasing lithium ions. If necessary, each of the positive-electrode active material layers 21B may further contain an additional material, for example, a positive-electrode binder or a positive-electrode conductive agent. Details of the positive-electrode binder and the positive-electrode conductive agent are the same as those of the negative-electrode binder and the negative-electrode conductive agent described above.

As the positive-electrode material, a Li-containing compound is preferred because a high energy density is provided. Examples of the Li-containing compound include a complex oxide that contains, as constituent elements, Li and a transition metal element; and a phosphate compound that contains, as constituent elements, Li and a transition metal element. It is preferred that the transition metal element be one or two or more of Co, Ni, Mn, and Fe. This is because a higher voltage is provided. The complex oxide and the phosphate compound are expressed as, for example, Li_(x)M₁₁O₂ and Li_(y)M₁₂PO₄, respectively, wherein M11 and M12 each represent one or more transition metal elements, and the values of x and y vary depending on a charge-discharge state of the battery and are usually 0.05≦x≦1.10 and 0.05≦y≦1.10. In particular, when the positive-electrode material contains Ni or Mn, the volume stability tends to be improved.

Examples of the complex oxide containing Li and a transition metal element include Li_(x)CoO₂, Li_(x)NiO₂, and a LiNi-based complex oxide represented by formula (1). Examples of the phosphate compound containing Li and a transition metal element include LiFePO₄ and LiFe_(1-u)Mn_(u)PO₄ (u<1). In this case, a high battery capacity and excellent cycle characteristics are provided. The positive-electrode material may be a material other than the foregoing materials. Examples thereof include materials represented by Li_(x)M_(14y)O₂ (wherein M14 represents at least one selected from Ni and M13 described in formula (1); x>1; and y represents any value).

LiNi_(1-x)M13_(x)O₂  (1)

(wherein M13 represents at least one selected from Co, Mn, Fe, Al, V, Sn, Mg, Ti, Sr, Ca, Zr, Mo, Tc, Ru, Ta, W, Re, Y, Cu, Zn, Ba, B, Cr, Si, Ga, P, Sb, and Nb; and x is 0.005<x<0.5).

Further examples of the positive-electrode material include oxides, disulfides, chalcogenides, and conductive polymers. Examples of oxides include titanium oxide, vanadium oxide, and manganese dioxide. Examples of disulfides include titanium disulfide and molybdenum sulfide. An example of chalcogenides is niobium selenide. Examples of conductive polymers include sulfur, polyaniline, and polythiophene.

Negative Electrode

The negative electrode 22 has the same structure as that of the foregoing negative electrode for a lithium-ion secondary battery. For example, the negative electrode 22 includes a negative-electrode active material layer 22B provided on each surface of a negative-electrode collector 22A. The structures of the negative-electrode collector 22A and the negative-electrode active material layers 22B are the same as those of the negative-electrode collector 1 and the negative-electrode active material layers 2. The chargeable capacity of the negative-electrode material capable of occluding and releasing lithium ions is preferably higher than the discharge capacity of the positive electrode 21 in order to prevent metallic Li from being unintentionally deposited during charge and discharge.

As illustrated in FIG. 4, for example, each of the positive-electrode active material layers 21B is arranged on a portion (for example, a middle region in the longitudinal direction) of a corresponding one of the surfaces of the positive-electrode collector 21A. Meanwhile, for example, each of the negative-electrode active material layers 22B is arranged on the whole of a corresponding one of the surfaces of the negative-electrode collector 22A. Thus, each of the negative-electrode active material layers 22B is arranged in a region (opposed region R1) of the negative-electrode collector 22A which is opposed to a corresponding one of the positive-electrode active material layers 21B, and a region (non-opposed region R2) of the negative-electrode collector 22A which is not opposed to the corresponding positive-electrode active material layer 21B. In this case, a portion of each negative-electrode active material layer 22B arranged in the opposed region R1 is associated with charge and discharge, whereas a portion arranged in the non-opposed region R2 has little association with charge and discharge. In FIG. 4, shaded areas indicate the positive-electrode active material layer 21B and the negative-electrode active material layer 22B.

As described above, each of the negative-electrode active material in the negative-electrode active material layers 22B has a predetermined composition (atomic ratio x) and optionally contains Li in an uncharged state. However, the negative-electrode active material layers 22B might be deformed or broken by expansion and contraction during charge and discharge. Thus, the composition of the negative-electrode active material and so forth may be changed from states at the time of the formation of the negative-electrode active material layers 22B. However, in the non-opposed region R2, the formation states of the negative-electrode active material layers 22B are little affected by charge and discharge and are maintained. Thus, the composition of the negative-electrode active material (atomic ratio x and Ml ratio), the proportions (atomic ratio) of the bonding states of Si atoms bonded to O atoms, and so forth are preferably are preferably investigated in the negative-electrode active material layers 22B in the non-opposed region R2. This is because, for example, the composition of the negative-electrode active material can be investigated reproducibly and accurately independent of charge-discharge history (e.g., whether charge and discharge are performed or not, and the number of times of charge and discharge).

The maximum utilization factor in a fully charged state of the negative electrode 22 (hereinafter, referred to simply as a “negative-electrode utilization factor”) is not particularly limited. Any negative-electrode utilization factor may be set in response to the ratio of the capacity of the positive electrode 21 to the capacity of the negative electrode 22.

The foregoing “negative-electrode utilization factor” is expressed as utilization factor Z (%)=(X/Y)×100, where X represents the amount of lithium ions occluded in the negative electrode 22 per unit area in a fully charged state, and Y represents the amount of lithium ions that can be electrochemically occluded in the negative electrode 22 per unit area.

For example, the amount X occluded can be determined by the following procedure. First, the secondary battery is charged to a fully charged state. The secondary battery is then disassembled to cut out a portion (test piece of the negative electrode) of the negative electrode 22 opposed to the positive electrode 21. Next, an evaluation battery including metallic lithium serving as a counter electrode is assembled using the test piece of the negative electrode. Finally, the evaluation battery is discharged to measure the discharge capacity at the time of initial discharge. The discharge capacity is divided by the area of the test piece of the negative electrode to determine the amount X occluded. In this case, the term “discharge” indicates that a current flows in a direction where lithium ions are released from the test piece of the negative electrode. For example, the battery is subjected to constant current discharge at a constant current, for example, at a current density of 0.1 mA/cm², until the battery voltage reaches 1.5 V.

Meanwhile, for example, the amount Y occluded is determined by subjecting the foregoing discharged evaluation battery to constant voltage and constant current charge until the battery voltage reaches 0 V, measuring the charge capacity, and dividing the charge capacity by the area of the test piece of the negative electrode. In this case, the term “charge” indicates that a current flows in a direction where lithium ions are occluded in the test piece of the negative electrode. For example, the battery is subjected to constant voltage charge at a current density of 0.1 mA/cm² and a battery voltage of 0 V until the current density reaches 0.02 mA/cm².

In particular, the negative-electrode utilization factor is preferably in the range of 35% to 80% because excellent cycle characteristics, initial charge-discharge characteristics, and load characteristics are provided.

Separator

The separator 23 isolates the positive electrode 21 from the negative electrode 22 to prevent the occurrence of a short circuit due to the contact of both electrodes and allows lithium ions to pass therethrough. The separator 23 is formed of, for example, a porous film of a synthetic resin or a ceramic material. The separator 23 may be formed of a laminated film in which two or more porous films are stacked. Examples of the synthetic resin include polytetrafluoroethylene, polypropylene, and polyethylene.

Electrolytic Solution

The separator 23 is impregnated with an electrolytic solution, which is a liquid electrolyte. The electrolytic solution is formed by dissolution of an electrolyte salt in a solvent. The electrolytic solution may contain an additional material, such as an additive, if necessary.

The solvent contains one or two or more of nonaqueous solvents, such as organic solvents. Examples of nonaqueous solvents include ethylene carbonate, propylene carbonate, butylene carbonate, dimethyl carbonate, diethyl carbonate, ethyl methyl carbonate, methyl propyl carbonate, γ-butyrolactone, γ-valerolactone, 1,2-dimethoxyethane, tetrahydrofuran, 2-methyltetrahydrofuran, tetrahydropyran, 1,3-dioxolane, 4-methyl-1,3-dioxolane, 1,3-dioxane, 1,4-dioxane, methyl acetate, ethyl acetate, methyl propionate, ethyl propionate, methyl butyrate, methyl isobutyrate, methyl trimethylacetate, ethyl trimethylacetate, acetonitrile, glutaronitrile, adiponitrile, methoxyacetonitrile, 3-methoxypropionitrile, N,N-dimethylformamide, N-methylpyrrolidinone, N-methyloxazolidinone, N,N′-dimethylimidazolidinone, nitromethane, nitroethane, sulfolane, trimethyl phosphate, and dimethyl sulfoxide. In this case, excellent battery capacity, cycle characteristics, and storage characteristics are provided.

In particular, at least one selected from ethylene carbonate, propylene carbonate, dimethyl carbonate, diethyl carbonate, and ethyl methyl carbonate is preferred because superior characteristics are provided. In this case, a combination of a high-viscosity (high dielectric constant) solvent (for example, dielectric constant ∈≧30), e.g., ethylene carbonate or propylene carbonate, and a low-viscosity solvent (for example, viscosity≦1 mPa·s), e.g., dimethyl carbonate, ethyl methyl carbonate, or diethyl carbonate, is more preferred because the dissociation property of the electrolyte salt and ion mobility are improved.

In particular, the nonaqueous solvent preferably contains at least one of a halogenated chain carbonate and a halogenated cyclic carbonate. This is because a stable coating film is formed on a surface of the negative electrode 22 during charge and discharge, thereby inhibiting the decomposition reaction of the electrolytic solution. The halogenated chain carbonate indicates a chain carbonate containing a halogen serving as a constituent element. In other words, the halogenated chain carbonate indicates a chain carbonate in which at least one hydrogen atom is substituted with a halogen. The halogenated cyclic carbonate indicates a cyclic carbonate containing a halogen serving as a constituent element. In other words, the halogenated cyclic carbonate indicates a cyclic carbonate in which at least one H is substituted with a halogen.

The type of halogen is not particularly limited. In particular, F, Cl, or Br is preferred, and F is more preferred. This is because F provides a higher effect than those of other halogens. With respect to the number of halogen atoms, two halogen atoms are more preferable than one halogen atom. Furthermore, three or more halogen atoms may be used. The reason for this is that the ability to form a protective film is increased and a stronger and stabler coating film is formed, thereby further inhibiting the decomposition reaction of the electrolytic solution.

Examples of the halogenated chain carbonate include fluoromethyl methyl carbonate, bis(fluoromethyl) carbonate, and difluoromethyl methyl carbonate. Examples of the halogenated cyclic carbonate include 4-fluoro-1,3-dioxolan-2-one, and 4,5-difluoro-1,3-dioxolan-2-one. For the halogenated cyclic carbonate, geometrical isomers are included. The proportions of the halogenated chain carbonate and the halogenated cyclic carbonate in the nonaqueous solvent are each in the range of, for example, 0.01% by weight to 50% by weight.

The nonaqueous solvent preferably contains an unsaturated carbon bond cyclic carbonate. This is because a stable coating film is formed on a surface of the negative electrode 22 during charge and discharge to inhibit the decomposition reaction of the electrolytic solution. The unsaturated carbon bond cyclic carbonate indicates a cyclic carbonate having one or two or more unsaturated carbon bonds. In other words, the unsaturated carbon bond cyclic carbonate indicates a cyclic carbonate in which an unsaturated carbon bond is introduced into any portion. Examples of the unsaturated carbon bond cyclic carbonate include vinylene carbonate and vinyl ethylene carbonate. The proportion of the unsaturated carbon bond cyclic carbonate in the nonaqueous solvent is in the range of, for example, 0.01% by weight to 10% by weight.

The nonaqueous solvent preferably contains a sultone (cyclic sulfonate) because the chemical stability of the electrolytic solution is improved. Examples of the sultone include propane sultone and propene sultone. The proportion of the sultone is in the range of, for example, 0.5% by weight to 5% by weight.

The nonaqueous solvent preferably contains an acid anhydride because the chemical stability of the electrolytic solution is improved. Examples of the acid anhydride include carboxylic anhydrides, disulfonic anhydrides, and carboxylic-sulfonic anhydrides. Examples of carboxylic anhydrides include succinic anhydride, glutaric anhydride, and maleic anhydride. Examples of disulfonic anhydrides include ethanedisulfonic anhydride and propanedisulfonic anhydride. Examples of carboxylic-sulfonic anhydrides include sulfobenzoic anhydride, sulfopropionic anhydride, and sulfobutyric anhydride. The proportion of the acid anhydride in the nonaqueous solvent is in the range of, for example, 0.5% by weight to 5% by weight.

The electrolyte salt contains one or two or more light metal salts, such as Li salts. Examples of Li salts include LiPF₆, LiBF₄, LiClO₄, LiAsF₆, LiB(C₆H₅)₄, LiCH₃SO₃, LiCF₃SO₃, LiAlCl₄, Li₂SiF₆, LiCl, and LiBr. Another Li salt may be used. This is because excellent battery capacity, cyclic characteristics, storage characteristics, and so forth are provided.

Among these compounds, one or two or more of LiPF₆, LiBF₄, LiClO₄, and LiAsF₆ are preferred. LiPF₆ or LiBF₄ is preferred. LiPF₆ is more preferred. This is because the internal resistance is reduced to achieve superior characteristics.

The electrolyte salt content is preferably in the range of 0.3 mol/kg to 3.0 mol/kg with respect to the solvent because a high ionic conductivity is provided.

Operation of Secondary Battery

When the prismatic secondary battery is charged, for example, lithium ions released from the positive electrode 21 are occluded in the negative electrode 22 through the electrolytic solution. Furthermore, when the prismatic secondary battery is discharged, for example, lithium ions released from the negative electrode 22 are occluded in the positive electrode 21 through the electrolytic solution.

Method for Producing Secondary Battery

The secondary battery is produced by, for example, a procedure described below.

First, the positive electrode 21 is formed. The positive-electrode active material and, if necessary, the positive-electrode binder, the positive-electrode conductive agent, and so forth are mixed together to form a positive-electrode mixture. The positive-electrode mixture is dispersed in an organic solvent or the like to form a paste-like slurry of the positive-electrode mixture. Next, the paste-like slurry of the positive-electrode mixture is applied to the positive-electrode collector 21A with a coating apparatus, for example, a doctor blade or a bar coater, and dried to form the positive-electrode active material layers 21B. Finally, the positive-electrode active material layers 21B are subjected to compression forming with a roll press or the like while being heated, if necessary. In this case, the compression forming may be repeated plural times.

Next, the negative-electrode active material layers 22B are formed on the negative-electrode collector 22A by a procedure the same as the foregoing procedure for forming the negative electrode 22 for a lithium-ion secondary battery.

Next, the battery element 20 is formed. First, the positive-electrode lead 24 is attached to the positive-electrode collector 21A by a welding method or the like. The negative-electrode lead 25 is attached to the negative-electrode collector 22A by a welding method or the like. Then the positive electrode 21 and the negative electrode 22 are stacked with the separator 23 provided therebetween. The resulting stack is spirally wound in a longitudinal direction. Finally, the resulting spirally wound body is formed so as to have a flattened shape.

Finally, the secondary battery is assembled. First, the battery element 20 is placed in the battery can 11. The insulating plate 12 is placed on the battery element 20. Next, the positive-electrode lead 24 is attached to the positive-electrode pin 15 by a welding method or the like. The negative-electrode lead 25 is attached to the battery can 11 by a welding method or the like. In this case, the battery cover 13 is fixed to an open end portion of the battery can 11 by a laser welding method or the like. Finally, the electrolytic solution is injected into the battery can 11 from the injection hole 19 to impregnate the separator 23 with the electrolytic solution, and then the injection hole 19 is sealed with the sealing member 19A.

Function and Effect of Secondary Battery

For the prismatic secondary battery, the negative electrode 22 has the same structure as that of the foregoing negative electrode for a lithium-ion secondary battery, thereby providing the same effects. It is thus possible to provide excellent battery characteristics, such as cycle characteristics, initial charge-discharge characteristics, and load characteristics. Effects other than these effects are the same as those of the negative electrode for a lithium-ion secondary battery.

2-2. Cylindrical Type

FIGS. 5 and 6 are sectional views illustrating a structure of a cylindrical lithium-ion secondary battery. FIG. 6 is a partially enlarged view of a spirally wound electrode 40 illustrated in FIG. 5. The cylindrical secondary battery will be described below with reference to components of the foregoing prismatic secondary battery, as necessary.

Structure of Secondary Battery

The cylindrical secondary battery mainly includes the spirally wound electrode 40 and a pair of insulating plates 32 and 33 in a substantially hollow cylindrical-shaped battery can 31. The spirally wound electrode 40 is formed of a spirally wound laminate in which a positive electrode 41 and a negative electrode 42 are stacked with a separator 43 provided therebetween and spirally wound.

The battery can 31 has a hollow structure in which an end portion of the battery can 31 is closed and the other end portion thereof is opened. The battery can 31 is composed of, for example, a material the same as that of the battery can 11. The pair of insulating plates 32 and 33 are arranged in such a manner that the spirally wound electrode 40 is sandwiched therebetween at the top and the bottom of the spirally wound electrode body 40 and that the pair of insulating plates 32 and 33 extend in a direction perpendicular to a peripheral winding surface.

In the open end portion of the battery can 31, a battery cover 34, a safety valve mechanism 35, and a positive temperature coefficient device (PTC device) 36 are caulked with a gasket 37. The battery can 31 is sealed. The battery cover 34 is composed of, for example, a material the same as that of the battery can 31. The safety valve mechanism 35 and the positive temperature coefficient device 36 are arranged inside the battery cover 34. The safety valve mechanism 35 is electrically connected to the battery cover 34 through the positive temperature coefficient device 36. In the safety valve mechanism 35, if the internal pressure of the secondary battery is increased to a predetermined value or higher by an internal short-circuit or externally applied heat, a disk plate 35A is reversed to disconnect the electrical connection between the battery cover 34 and the spirally wound electrode 40. The positive temperature coefficient device 36 exhibits an increase in resistance with increasing temperature and thus prevents abnormal heat generation due to a large current. The gasket 37 is composed of, for example, an insulating material. The surface of the gasket 37 may be coated with asphalt.

A center pin 44 may be interposed in the center of the spirally wound electrode 40. A positive-electrode lead 45 composed of a conductive material, such as Al, is connected to the positive electrode 41. A negative-electrode lead 46 composed of a conductive material, such as Ni, is connected to the negative electrode 42. The positive-electrode lead 45 is attached to the safety valve mechanism 35 by welding or the like to establish electrical connection with the battery cover 34. The negative-electrode lead 46 is attached to the battery can 31 by welding or the like to establish electrical connection with the battery can 31.

The positive electrode 41 includes, for example, a positive-electrode active material layer 41B provided on each surface of a positive-electrode collector 41A. The negative electrode 42 has the same structure as the foregoing negative electrode for a lithium-ion secondary battery. For example, the negative electrode 42 includes a negative-electrode active material layer 42B provided on each surface of a negative-electrode collector 42A. The structures of the positive-electrode collector 41A, the positive-electrode active material layers 41B, the negative-electrode collector 42A, the negative-electrode active material layers 42B, and the separator 43 are the same as those of the positive-electrode collector 21A, the positive-electrode active material layers 21B, the negative-electrode collector 22A, the negative-electrode active material layers 22B, and the separator 23, respectively. The composition of an electrolytic solution with which the separator 43 is impregnated is the same as that of the electrolytic solution used in the prismatic secondary battery.

Operation of Secondary Battery

When the cylindrical secondary battery is charged, for example, lithium ions released from the positive electrode 41 are occluded in the negative electrode 42 through the electrolytic solution. Furthermore, when the cylindrical secondary battery is discharged, for example, lithium ions released from the negative electrode 42 are occluded in the positive electrode 41 through the electrolytic solution.

Method for Producing Secondary Battery

The cylindrical secondary battery is produced by, for example, a procedure described below. First, for example, the positive-electrode active material layer 41B is formed on each of the surfaces of the positive-electrode collector 41A to form the positive electrode 41 in the same way as the procedure for forming the positive electrode 21. The negative-electrode active material layer 42B is formed on each of the surfaces of the negative-electrode collector 42A to form the negative electrode 42 in the same way as the procedure for forming the negative electrode 22. Next, the positive-electrode lead 45 is attached to the positive electrode 41 by a welding method or the like. The negative-electrode lead 46 is attached to the negative electrode 42 by a welding method or the like. Then the positive electrode 41 and the negative electrode 42 are stacked with the separator 43 provided therebetween. The resulting stack is spirally wound to form a spirally wound electrode 40. The center pin 44 is inserted into the center of the spirally wound electrode 40. The spirally wound electrode 40 is placed in the battery can 31 while being sandwiched between the pair of insulating plates 32 and 33. In this case, the positive-electrode lead 45 is attached to the safety valve mechanism 35 by a welding method or the like. An end portion of the negative-electrode lead 46 is attached to the battery can 31 by a welding method or the like. Subsequently, the electrolytic solution is injected into the battery can 31, thereby impregnating the separator 43 with the electrolytic solution. Finally, the battery cover 34, the safety valve mechanism 35, and the positive temperature coefficient device 36 are attached to the open end portion of the battery can 31 and then are caulked with the gasket 37.

Function and Effect of Secondary Battery

For the cylindrical secondary battery, the negative electrode 42 has the same structure as that of the foregoing negative electrode for a lithium-ion secondary battery, thereby providing the same effects as those of the prismatic secondary battery.

2-3. Laminated-Film Type

FIG. 7 is an exploded perspective view illustrating a structure of a laminated-film-type lithium-ion secondary battery. FIG. 8 is an enlarged cross-sectional view taken along line VIII-VIII in FIG. 7 that illustrates a spirally wound electrode 50.

Structure of Secondary Battery

The laminated-film-type secondary battery mainly includes the spirally wound electrode 50 in film-shaped package members 59. The spirally wound electrode 50 is formed of a spirally wound laminate in which a positive electrode 53 and a negative electrode 54 are stacked with separators 55 and electrolyte layers 56 provided therebetween and spirally wound. A positive-electrode lead 51 is attached to the positive electrode 53. A negative-electrode lead 52 is attached to the negative electrode 54. The outermost portion of the spirally wound electrode 50 is protected by a protective tape 57.

For example, the positive-electrode lead 51 and the negative-electrode lead 52 extend from the inside to the outside of the package members 59 in one direction. The positive-electrode lead 51 is composed of a conductive material, e.g., Al. The negative-electrode lead 52 is composed of a conductive material, e.g., Cu, Ni, stainless steel. These materials each have a sheet shape or a mesh shape.

For example, each of the package members 59 is formed of a laminated film in which a bonding layer, a metal layer, and a surface protective layer are stacked in that order. For the laminated films, for example, peripheral portions of the bonding layers of two laminated films are bonded together by fusion bonding or with an adhesive in such a manner that the bonding layers face the spirally wound electrode 50. Each of the bonding layers is formed of a film of polyethylene, polypropylene, or the like. The metal layer is formed of Al foil or the like. The surface protective layer is formed of a film of nylon, polyethylene terephthalate, or the like.

In particular, as each package member 59, an aluminum-laminated film in which a polyethylene film, aluminum foil, and a nylon film are stacked in that order is preferred. However, each package member 59 may be formed of a laminated film having another stacking structure. Alternatively, each package member 59 may be formed of a polymer film of polypropylene or a metal film.

Contact films 58 configured to prevent the entry of outside air are arranged between the positive-electrode lead 51 and the package members 59 and between the negative-electrode lead 52 and the package members 59. Each of the contact films 58 is composed of a material adhesive to the positive-electrode lead 51 and the negative-electrode lead 52. Examples of the material include polyolefin resins, such as polyethylene, polypropylene, modified polyethylene, and modified polypropylene.

The positive electrode 53 includes, for example, a positive-electrode active material layer 53B provided on each surface of a positive-electrode collector 53A. The negative electrode 54 has the same structure as the foregoing negative electrode for a lithium-ion secondary battery. For example, the negative electrode 54 includes a negative-electrode active material layer 54B provided on each surface of a negative-electrode collector 54A. The structures of the positive-electrode collector 53A, the positive-electrode active material layers 53B, the negative-electrode collector 54A, and the negative-electrode active material layers 54B are the same as those of the positive-electrode collector 21A, the positive-electrode active material layers 21B, the negative-electrode collector 22A, and the negative-electrode active material layers 22B, respectively. The structure of each of the separators 55 is the same as that of the separator 23.

Each of the electrolyte layers 56 is formed of a component in which an electrolytic solution is held by a polymeric compound. Each electrolyte layer 56 may contain additional material, such as an additive, if necessary. The electrolyte layer 56 is composed of what is called a gel-like electrolyte. The gel-like electrolyte is preferred because a high ionic conductivity (e.g., 1 mS/cm or more at room temperature) is obtained and the leakage of the electrolytic solution from the battery is prevented.

The polymeric compound contains one or two or more compounds described below. Examples thereof include polyacrylonitrile, polyvinylidene fluoride, polytetrafluoroethylene, polyhexafluoropropylene, polyethylene oxide, polypropylene oxide, polyphosphazene, polysiloxane, polyvinyl fluoride, polyvinyl acetate, polyvinyl alcohol, polymethyl methacrylate, polyacrylic acid, polymethacrylic acid, styrene-butadiene rubber, nitrile-butadiene rubber, polystyrene, polycarbonate, and copolymers of vinylidene fluoride and hexafluoropropylene. Among these compounds, polyvinylidene fluoride or copolymers of vinylidene fluoride and hexafluoropropylene are preferred because of their good electrochemical stability.

For example, the electrolytic solution has the same composition as the composition of the electrolytic solution used in the prismatic secondary battery. However, in the electrolyte layers 56 composed of a gel-like electrolyte, the solvent of the electrolytic solution indicates a wide concept including not only a liquid solvent but also a material which is capable of dissociating an electrolyte salt and which has ionic conductivity. Thus, in the case where a polymeric compound having ionic conductivity is used, the polymeric compound is included in the concept of the solvent.

Instead of the gel-like electrolyte layers 56, an electrolytic solution may be used. In this case, the separators 55 are impregnated with the electrolytic solution.

Operation of Secondary Battery

When the laminated-film-type secondary battery is charged, lithium ions released from the positive electrode 53 are occluded in the negative electrode 54 through the electrolyte layers 56. Furthermore, for example, when the laminated-film-type secondary battery is discharged, lithium ions released from the negative electrode 54 are occluded in the positive electrode 53 through the electrolyte layers 56.

Method for Producing Secondary Battery

The laminated-film-type secondary battery including the gel-like electrolyte layers 56 is produced by, for example, three types of procedures described below.

In a first procedure, first, the positive electrode 53 and the negative electrode 54 are formed in the same ways as the procedures for forming the positive electrode 21 and the negative electrode 22. In this case, the positive-electrode active material layer 53B is formed on each surface of the positive-electrode collector 53A to form the positive electrode 53. The negative-electrode active material layer 54B is formed on each of the surfaces of the negative-electrode collector 54A to form the negative electrode 54. Next, a precursor solution including an electrolytic solution, a polymer compound, an organic solvent, and the like is prepared. The precursor solution is applied to the positive electrode 53 and the negative electrode 54 to form the gel-like electrolyte layers 56. Then the positive-electrode lead 51 is attached to the positive-electrode collector 53A by a welding method or the like. The negative-electrode lead 52 is attached to the negative-electrode collector 54A by a welding method or the like. Subsequently, the positive electrode 53 and the negative electrode 54 including the electrolyte layers 56 are stacked with the separators 55 and spirally wound to form the spirally wound electrode 50. The protective tape 57 is bonded to the outermost portion of the spirally wound electrode 50. Finally, the spirally wound electrode 50 is sandwiched between two film-shaped package members 59. The peripheral portions of the package members 59 are bonded together by a heat fusion method or the like to seal the spirally wound electrode 50 in the package members 59. In this case, the contact films 58 are interposed between the positive-electrode lead 51 and the package members 59 and between the negative-electrode lead 52 and the package members 59.

In a second procedure, first, the positive-electrode lead 51 is attached to the positive electrode 53. The negative-electrode lead 52 is attached to the negative electrode 54. Next, the positive electrode 53 and the negative electrode 54 are stacked with the separators 55 provided therebetween and spirally wound to form a spirally wound component serving as a precursor of the spirally wound electrode 50. The protective tape 57 is bonded to the outermost portion of the spirally wound component. Then the spirally wound component is sandwiched between two film-shaped package members 59. The peripheral portions except for a peripheral portion on one side are bonded by a heat fusion method or the like to accommodate the spirally wound component in the pouch-like package members 59. Next, an electrolytic composition containing an electrolytic solution, a monomer serving as a raw material of a polymeric compound, a polymerization initiator, and, optionally, an additional material, such as a polymerization inhibitor, is prepared. The resulting electrolytic composition is injected into the pouch-like package members 59. The opening portion of the package members 59 is sealed by a heat fusion method or the like. Finally, the monomer is thermally polymerized to form a polymeric compound, thereby resulting in the gel-like electrolyte layers 56.

In a third procedure, first, a spirally wound component is formed and accommodated in the pouch-like package members 59 in the same way as the second procedure, except that the separators 55 each having both surfaces coated with a polymeric compound is used. Examples of the polymeric compound applied to the separators 55 include polymers from vinylidene fluoride (homopolymers, copolymers, and multi-component copolymers). Specific examples thereof include polyvinylidene fluoride; two-component copolymers of vinylidene fluoride and hexafluoropropylene; and three-component copolymers of vinylidene fluoride, hexafluoropropylene, and chlorotrifluoroethylene. In combination with a polymer from vinylidene fluoride, one or two or more other polymeric compounds may be used. Next, the electrolytic solution is prepared and injected into the package members 59. The opening portion of the package members 59 is sealed by a heat fusion method or the like. Finally, the package members 59 are heated under load to bring the separators 55 into close contact with the positive electrode 53 and the negative electrode 54 with the polymeric compound. Thus, the polymeric compound is impregnated with the electrolytic solution. Thereby, the polymeric compound gels to form the electrolyte layers 56.

In the third procedure, swelling of the battery is suppressed, compared with the first procedure. A negligible amount of a monomer serving as a raw material for the polymeric compound, an organic solvent, or the like is left, compared with the second procedure, thereby satisfactorily controlling a step of forming the polymeric compound. Thus, the electrolyte layers 56 have sufficient adhesion to the positive electrode 53, the negative electrode 54, and the separators 55.

Function and Effect of Secondary Battery

For the laminated-film-type secondary battery, the negative electrode 54 has the same structure as that of the foregoing negative electrode for a lithium-ion secondary battery, thereby providing the same effects as those of the prismatic secondary battery.

3. Application of Lithium-Ion Secondary Battery

Application examples of the foregoing lithium-ion secondary battery will be described below.

The application of the lithium-ion secondary battery is not particularly limited as long as the lithium-ion secondary battery is applied to machines, devices, appliances, apparatuses, systems (combinations of a plurality of devices), and the like which can use the lithium-ion secondary battery as a power source for operation or a power storage source for accumulation of power. In the case where the lithium-ion secondary battery is used as a power source, the power source may be used as a main power source (a power source to be preferentially used) or an auxiliary power source (a power source to be used instead of the main power source or by switching from the main power source). The type of the main power source is not limited to the lithium-ion secondary battery.

The lithium-ion secondary battery is applied to, for example, the following applications. Examples of the applications include portable electronic devices, such as video cameras, digital still cameras, cellular phones, notebook personal computers, cordless telephones, headphone stereos, portable radios, portable television sets, and personal digital assistants; portable home appliances, such as electric shavers; backup power sources; storage devices, such as memory cards; electric tools, such as electric drills and electric saws; battery packs used as power sources for notebook personal computers and so forth; medical electronic devices, such as pacemakers and hearing aids; vehicles, such as electric vehicles (including hybrid vehicles); and energy storage systems, such as household battery systems storing power in case of emergency or the like. The lithium-ion secondary battery may be applied to applications other than the foregoing applications.

In particular, the lithium-ion secondary battery is effectively applied to, for example, a battery pack, an electric vehicle, a power storage system, an electric tool, or an electronic device. This is because such an application demands excellent battery characteristics; hence, the use of the lithium-ion secondary battery according to an embodiment of the present application effectively improves the characteristics. The battery pack refers to a power source including the lithium-ion secondary batteries and is what is called a set of batteries or the like. The electric vehicle refers to a vehicle that operates (runs) using the lithium-ion secondary battery as a power source for operation. As described above, the electric vehicle may include a vehicle (e.g., a hybrid vehicle) with a driving source in addition to the lithium-ion secondary battery. The power storage system refers to a system including the lithium-ion secondary battery as a power storage source. For example, in a household energy storage system, electric power is stored in the lithium-ion secondary battery serving as a power storage source. Electric power is consumed when necessary, so home appliances can be used. The electric tool refers to a tool having a moving part (such as a drill) that is movable using the lithium-ion secondary battery as a power source for operation. The electronic device refers to a device that performs various functions using the lithium-ion secondary battery for operation.

Some application examples of the lithium-ion secondary battery will be specifically described below. Configurations of the application examples described below are merely examples and thus can be appropriately changed.

3-1. Battery Pack

FIG. 9 illustrates a block configuration of a battery pack. For example, as illustrated in FIG. 10, the battery pack includes a controller 61, a power source 62, a switching unit 63, a current measurement unit 64, a temperature detecting unit 65, a voltage detecting unit 66, a switching controller 67, memory 68, a temperature detecting element 69, a current detecting resistance 70, a positive-electrode terminal 71, and a negative-electrode terminal 72 in a housing 60 composed of, for example, a plastic material.

The controller 61 controls the overall operation of the battery pack (including the usage state of the power source 62) and includes, for example, a central processing unit (CPU). The power source 62 includes one or two or more lithium-ion secondary batteries (not illustrated). The power source 62 refers to, for example, a set of batteries including two or more lithium-ion secondary batteries. These lithium-ion secondary batteries may be connected in series, in parallel, or in combination thereof. For example, the power source 62 includes six lithium-ion secondary batteries in which three sets of two batteries connected in parallel are connected in series.

The switching unit 63 is configured to switch the usage state of the power source 62 (availability of connection between the power source 62 and external equipment) in response to instructions from the controller 61. The switching unit 63 includes, for example, a charge control switch, a discharge control switch, a diode for charge, and a diode for discharge (all elements are not illustrated). Examples of the charge control switch and the discharge control switch include semiconductor switches formed of, for example, metal oxide semiconductor field-effect transistors (MOSFETs).

The current measurement unit 64 is configured to measure a current with the current detecting resistance 70 and to send the measurement results to the controller 61. The temperature detecting unit 65 is configured to measure a temperature with the temperature detecting element 69 and to send the measurement results to the controller 61. For example, the temperature measurement results are used when the controller 61 controls charge and discharge at the time of abnormal heat generation and when the controller 61 performs correction at the time of the calculation of remaining battery capacity. The voltage detecting unit 66 is configured to measure the voltage of the lithium-ion secondary batteries in the power source 62, subject the measured voltage to analog-to-digital (A/D) conversion, and send the resulting digital output to the controller 61.

The switching controller 67 is configured to control the operation of the switching unit 63 in response to signals from the current measurement unit 64 and the voltage detecting unit 66.

The switching controller 67 controls the switching unit 63 in such a manner that, for example, when the battery voltage reaches an overcharge detection voltage, the switching unit 63 (charge control switch) is disconnected so as not to allow a charging current to flow through the current path of the power source 62. This permits the power source 62 only to discharge with the diode for discharge. For example, the switching controller 67 is configured to interrupt a charging current when a large current flows during charging.

Furthermore, the switching controller 67 controls the switching unit 63 in such a manner that, for example, when the battery voltage reaches an over-discharge detection voltage, the switching unit 63 (discharge control switch) is disconnected so as not to allow a discharge current to flow through the current path of the power source 62. This permits the power source 62 only to charge with the diode for charge. For example, the switching controller 67 is configured to interrupt a discharge current when a large current flows during discharging.

In the lithium-ion secondary battery, for example, the overcharge detection voltage is 4.20 V±0.05 V, and the over-discharge detection voltage is 2.4 V±0.1 V.

An example of the memory 68 is electrically erasable programmable read-only memory (EEPROM), which is nonvolatile memory. For example, the memory 68 stores a numerical value calculated by the controller 61 and information about the lithium-ion secondary batteries (for example, initial internal resistance) measured in the production process. In the case where the full charge capacity of the lithium-ion secondary batteries is stored in the memory 68, the controller 61 can obtain information about remaining capacity and so forth.

The temperature detecting element 69 is configured to measure the temperature of the power source 62 and to send the measurement results to the controller 61. An example of the temperature detecting element 69 is a thermistor.

The positive-electrode terminal 71 and the negative-electrode terminal 72 are terminals for connection to external equipment (e.g., a notebook personal computer) operated by the battery pack or to external equipment (e.g., a charger) used to charge the battery pack. The charge and discharge of the power source 62 are performed through the positive-electrode terminal 71 and the negative-electrode terminal 72.

3-2. Electric Vehicle

FIG. 10 illustrates a block configuration of a hybrid vehicle as an example of an electric vehicle. For example, as illustrated in FIG. 10, the electric vehicle includes a controller 74, an engine 75, a power source 76, a driving motor 77, a differential device 78, a dynamo 79, a transmission 80, a clutch 81, inverters 82 and 83, and various sensors 84 in a metal chassis 73. The electric vehicle further includes, for example, an axle shaft 85 for front wheels, the axle shaft 85 being connected to the differential device 78 and the transmission 80, front wheels 86, an axle shaft 87 for rear wheels, and rear wheels 88.

The electric vehicle can run using any one of the engine 75 and the motor 77 as a driving source. The engine 75 serves as a main driving source, such as a gasoline engine. In the case where the engine 75 is used as a driving source, for example, the driving force (torque) of the engine 75 is transmitted to the front wheels 86 or the rear wheels 88 through the differential device 78, the transmission 80, and clutch 81 serving as drive members. The torque of the engine 75 is also transmitted to the dynamo 79 and allows the dynamo 79 to generate alternating-current (AC) power. The AC power is converted into direct-current (DC) power by the inverter 83. The resulting DC power is stored in the power source 76. Meanwhile, in the case where the motor 77 serving as a convertor is used as a driving source, power (DC power) supplied from the power source 76 is converted into AC power by the inverter 82. The motor 77 is driven by the AC power. The driving force (torque) obtained by conversion of electric power using the motor 77 is transmitted to, for example, the front wheels 86 or the rear wheels 88 through the differential device 78, the transmission 80, and clutch 81 serving as drive members.

When the electric vehicle slows down with a brake mechanism (not illustrated), the resistance during the slowing down may be transmitted to the motor 77 in the form of torque, and the motor 77 may generate AC power using the torque. Preferably, the resulting AC power is converted into DC power by the inverter 82, and the regenerative DC power is stored in the power source 76.

The controller 74 controls the operation of the overall electric vehicle and includes, for example, a central processing unit (CPU). The power source 76 includes one or two or more lithium-ion secondary batteries (not illustrated). The power source 76 may be configured to be capable of storing power by establishing connection with an external power source and receiving power from the external power source. For example, the various sensors 84 are used to control the number of revolutions of the engine 75 and to control the position (throttle position) of a throttle valve (not illustrated). The various sensors 84 include, for example, a speed sensor, an acceleration sensor, and an engine speed sensor.

As described above, the hybrid vehicle has been described as an electric vehicle. The electric vehicle may be a vehicle (electric vehicle) operated by the power source 76 and the motor 77 without the engine 75.

3-3. Power Storage System

FIG. 11 illustrates a block configuration of a power storage system. For example, as illustrated in FIG. 11, the power storage system includes a controller 90, a power source 91, a smart meter 92, and a power hub 93 in a house 89, e.g., a general house or commercial building.

Here, for example, the power source 91 is connected to electric equipment 94 installed in the house 89 and can be connected to an electric vehicle 96 parked outside the house 89. Furthermore, for example, the power source 91 is connected to a private generator 95 mounted on the house 89 via the power hub 93 and can be connected to an external centralized power grid 97 via the smart meter 92 and the power hub 93.

The electric equipment 94 includes one or two or more home appliances, such as refrigerators, television sets, and water heaters. The private generator 95 includes one or two or more generators, such as solar photovoltaic generators and wind generators. The electric vehicle 96 includes one or two or more vehicles, such as electric vehicles, electric motorcycles, and hybrid vehicles. The centralized power grid 97 includes one or two or more power grids connected to, for example, thermal power plants, nuclear power plants, hydroelectric power stations, and wind farms.

The controller 90 controls the operation of the overall power storage system (including the usage state of the power source 91) and includes, for example, a CPU. The power source 91 includes one or two or more lithium-ion secondary batteries (not illustrated). The smart meter 92 is, for example, a network-ready electrical meter installed in the house 89, which is on the power demand side and can communicate with the power supply side. Thus, for example, the smart meter 92 is configured to control a balance between supply and demand in the house 89 while communicating with the outside, if necessary, thereby efficiently and stably supplying energy.

In this power storage system, for example, power is stored in the power source 91 from the centralized power grid 97, which is an external power source, via the smart meter 92 and the power hub 93. Furthermore, power is stored in the power source 91 from the private generator 95, which is an independent power source, via the power hub 93. The power stored in the power source 91 is supplied to the electric equipment 94 or the electric vehicle 96, if necessary, in response to instructions from the controller 90. Thus, the electric equipment 94 can be operated, and the electric vehicle 96 can be charged. That is, the power storage system is a system capable of storing and supplying power in the house 89 using the power source 91.

Power stored in the power source 91 can be desirably used. For example, power can be stored in the power source 91 from the centralized power grid 97 during late-night hours in which the market price of electricity is low. The power stored in the power source 91 can be used during daytime hours in which the market price of electricity is high.

The foregoing power storage system may be installed for each house (family) or may be installed for each set of a plurality of houses (a plurality of families).

3-4. Electric Tool

FIG. 12 illustrates a block configuration of an electric tool. For example, as illustrated in FIG. 12, the electric tool is an electric drill that includes a controller 99 and a power source 100 in a main body 98 composed of, for example, a plastic material. For example, a drill portion 101, which is a moving part, is rotatably attached to the main body 98.

The controller 99 controls the overall operation of the electric tool (including the usage state of the power source 100) and includes, for example, a CPU. The power source 100 includes one or two or more lithium-ion secondary batteries (not illustrated). The controller 99 is configured to appropriately supply power from the power source 100 to the drill portion 101 in response to the operation of an operation switch (not illustrated) to drive the drill portion 101.

EXAMPLES

Examples of the present application will be described in detail below.

Experimental Example 1-1 to 1-10

Laminated-film-type secondary batteries illustrated in FIGS. 7 and 8 were produced by a procedure described below.

The positive electrode 53 was formed. First, 91 parts by mass of a positive-electrode active material (LiCoO₂), 6 parts by mass of a positive-electrode conductive agent (graphite), and 3 parts by mass of a positive-electrode binder (polyvinylidene fluoride: PVDF) were mixed together to form a positive-electrode mixture. The positive-electrode mixture was dispersed in an organic solvent (N-methyl-2-pyrrolidone: NMP) to form a paste-like slurry of the positive-electrode mixture. Then the slurry of the positive-electrode mixture was applied to both surface of the positive-electrode collector 53A with a coating apparatus and dried to form the positive-electrode active material layers 53B. As the positive-electrode collector 53A, strip-shaped aluminum foil (thickness: 12 μm) was used. Finally, the positive-electrode active material layers 53B were subjected to compression forming with a roll press. The thickness of each of the positive-electrode active material layers 53B was adjusted so as to prevent the deposition of metallic Li on the negative electrode 54 in a fully charged state.

Next, the negative electrode 54 was formed. First, materials constituting a negative-electrode active material were deposited on a substrate by an evaporation method. The deposited film was pulverized into the negative-electrode active material. In this case, powdered SiO_(x) and powdered metal Ml (Ni), which were raw materials, were co-deposited using a deflective electron beam evaporation source. During the deposition of the raw materials, the flow rate of O₂ or H₂ was adjusted to control the composition (atomic ratio x). Simultaneously, the input power was adjusted to control the ratio (Ml/(Si+O)). Furthermore, the deposition rate and the substrate temperature were adjusted to control the compound state in the negative-electrode active material. Simultaneously, the substrate temperature is adjusted to control the proportions (atomic ratios) of the bonding states of Si atoms bonded to O atoms. The presence or absence of the compound state indicates the presence or absence of SiMlO in the negative-electrode active material and, in this case, indicates the presence or absence of SiNiO. Detailed conditions are described in Table 1. Other conditions were described below. The negative-electrode active material had a median diameter of 5 μm. The deposition was performed in a vacuum state, i.e., at a pressure of 1×10⁻³ Pa, with a turbo-molecular pump.

Valence requirements described in Table 1 and other tables are as follows. Requirement 1 is that the proportions satisfy the relationship: Si⁴⁺<Si⁰⁺+Si¹⁺+Si²⁺+Si³⁺. Requirement 2 is that the proportions satisfy the relationships: Si⁴⁺+>Si⁰⁺, Si⁴⁺≧Si¹⁺, and Si⁴⁺≧Si²⁺. Requirement 3 is that the proportion of Si¹⁺ is less than 10 atomic percent. In the tables, “yes” and “no” indicate whether the foregoing requirements are satisfied or not.

Next, a negative-electrode active material and a precursor of a negative-electrode binder were mixed together in a dry weight ratio of 90:10. The resulting mixture was diluted with NMP to form a paste-like slurry of a negative-electrode mixture. In this case, a polyamic acid containing NMP and N,N-dimethylacetamide (DMAC) was used. Then the slurry of the negative-electrode mixture was applied to both surface of the negative-electrode collector 54A with a coating apparatus and dried. As the negative-electrode collector 54A, rolled Cu foil (thickness: 15 μm, ten-point height of irregularities Rz<0.5 μm) was used. Finally, in order to enhance binding properties, the resulting coating films were hot-pressed and baked in a vacuum atmosphere at 400° C. for 1 hour. Thereby, the negative-electrode binder (polyamide-imide) was formed, thus resulting in the negative-electrode active material layers 54B containing the negative-electrode active material and the negative-electrode binder. The thickness of each of the negative-electrode active material layers 54B was adjusted in such a manner that the negative-electrode utilization factor was 65%.

Next, an electrolyte salt (LiPF₆) was dissolved in a mixed solvent (ethylene carbonate (EC) and diethyl carbonate (DEC)) to prepare an electrolytic solution. In this case, with respect to the composition of the mixed solvent, the ratio by weight of EC to DEC was 50 to 50, and the proportion of the electrolyte salt was 1 mol/kg with respect to the mixed solvent.

Finally, the secondary battery was assembled. First, the positive-electrode lead 51 composed of Al was welded to an end of the positive-electrode collector 53A. The negative-electrode lead 52 composed of Ni was welded to an end of the negative-electrode collector 54A. Next, the positive electrode 53, the separator 55, the negative electrode 54, and the separator 55 were stacked in that order. The resulting stack was spirally wound in a longitudinal direction to form a spirally wound component serving as a precursor of the spirally wound electrode 50. The outermost portion of the spirally wound component was fixed with the protective tape 57 (adhesive tape). In this case, as each of the separators 55, a laminated film (thickness: 20 μm) in which a film mainly containing porous polyethylene was sandwiched between films mainly composed of porous polypropylene was used. Next, the spirally wound component was sandwiched between the package members 59. The peripheral portions except for a peripheral portion on one side were bonded by heat fusion to accommodate the spirally wound component in the pouch-like package members 59. In this case, as each of the package members 59, an aluminum-laminated film in which a nylon film (thickness: 30 μm), Al foil (thickness: 40 μm), and a non-stretched polypropylene film (thickness: 30 μm) were stacked in that order from the outside was used. Then the electrolytic solution was injected from an opening portion of the package members 59 to impregnate the separators 55 with the electrolytic solution, thereby forming the spirally wound electrode 50. Finally, the opening portion of the package members 59 was sealed by heat fusion in a vacuum atmosphere.

The cycle characteristics, the initial charge-discharge characteristics, and the load characteristics of the secondary batteries were investigated. Table 1 illustrates the results.

In the case where the cycle characteristics were investigated, first, one charge-discharge cycle was performed in an atmosphere with a temperature of 23° C. in order to stabilize the battery state. Subsequently, another charge-discharge cycle was performed to measure the discharge capacity. Next, the charge-discharge cycle was repeated until the number of cycles reached 100 cycles, and then the discharge capacity was measured. Finally, the cycle retention rate was calculated from the following expression: cycle retention rate (%)=(discharge capacity at 100th cycle/discharge capacity at second cycle)×100. In the case of charging, each secondary battery was charged at a constant current density of 3 mA/cm² until the voltage reached 4.2 V, and then the battery was charged at a constant voltage of 4.2 V until the current density reached 0.3 mA/cm². In the case of discharging, the battery was discharged at a constant current density of 3 mA/cm² until the voltage reached 2.5 V.

In the case where the initial charge-discharge characteristics were investigated, first, one charge-discharge cycle was performed in order to stabilize the battery state. Subsequently, each secondary battery was charged again to measure the charge capacity. Then the battery was discharged to measure the discharge capacity. Finally, the initial efficiency was calculated from the following expression: initial efficiency (%)=(discharge capacity/charge capacity)×100. The atmospheric temperature and charge-discharge conditions were the same as those in the case of investigating the cycle characteristics.

In the case of investigating the load characteristics, first, one charge-discharge cycle was performed in order to stabilize the battery state. Subsequently, the second cycle of the charge-discharge operation was performed to measure the discharge capacity. Then the third cycle of the charge-discharge operation was performed to measure the discharge capacity. Finally, the load retention rate was calculated from the following expression: load retention rate (%)=(discharge capacity at third cycle/discharge capacity at second cycle)×100. The atmospheric temperature and charge-discharge conditions were the same as those in the case of investigating the cycle characteristics, except that the discharge current density at the second cycle was changed to 0.2 mA/cm² and the discharge current density at the third cycle was changed to 1 mA/cm².

TABLE 1 Compound Valence Cycle Initial Load Experimental Proportion state requirement retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 rate (%) (%) rate (%) 1-1 SiO_(x) 1.2 Ni 1 present yes yes yes 81.0 76.0 94.0 1-2 5 81.1 81.1 96.0 1-3 10 81.1 81.8 97.0 1-4 15 81.3 81.9 97.5 1-5 20 81.5 81.9 97.5 1-6 30 81.4 81.8 98.0 1-7 50 81.3 81.9 98.0 1-8 60 81.0 81.9 98.0 1-9 SiO_(x) 1.2 Ni 10 absent yes yes yes 81.1 74.0 97.0 1-10 SiO_(x) 1.2 — — — — — — 80.0 67.0 92.0

In the case where the negative-electrode active material contained Si, O, and Ml (Ni), the cycle retention rate, the initial efficiency, and the load retention rate were increased, as compared with the case where Ml was not contained. In particular, in the case where the negative-electrode active material contained Ml, when the Ml ratio was 50 atomic percent or less and even 20 atomic percent, a reduction in battery capacity was suppressed, thereby resulting in a high battery capacity. In the case where the negative-electrode active material contained the compound (SiMlO), the initial efficiency was further increased, as compared with the compound was not contained.

Experimental Example 2-1 to 2-88

As illustrated in Tables 2 to 5, secondary batteries were produced by the same procedure as in Experimental Examples 1-1 to 1-8, except that different types, ratios, and combinations of Ml metals were used. Characteristics of each of the resulting secondary batteries were investigated. In this case, in order to perform co-deposition with powdered SiO_(y), other powdered metals Ml (e.g., Al) were used.

TABLE 2 Compound Valence Cycle Initial Load Experimental Proportion state requirement retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 rate (%) (%) rate (%) 2-1 SiO_(x) 1.2 Al 1 present yes yes yes 80.0 80.1 94.0 2-2 7 80.0 80.7 94.0 2-3 10 80.2 81.5 96.0 2-4 20 80.3 81.8 97.0 2-5 50 80.4 81.5 98.0 2-6 60 80.4 81.5 98.0 2-7 SiO_(x) 1.2 Fe 10 present yes yes yes 80.1 80.4 96.0 2-8 20 80.2 80.5 97.0 2-9 50 80.2 80.5 98.0 2-10 60 80.2 80.5 98.0 2-11 SiO_(x) 1.2 Cu 8 present yes yes yes 80.2 80.4 96.0 2-12 20 80.3 80.5 97.0 2-13 50 80.3 80.6 98.0 2-14 60 80.4 80.6 98.0 2-15 SiO_(x) 1.2 C 10 present yes yes yes 80.1 80.9 96.0 2-16 20 80.3 81.0 97.0 2-17 50 80.3 81.0 98.0 2-18 60 80.3 80.8 98.0 2-19 SiO_(x) 1.2 Mg 10 present yes yes yes 80.6 80.9 96.0 2-20 20 80.5 80.8 97.0 2-21 50 80.5 80.8 98.0 2-22 60 80.5 80.9 98.0 2-23 SiO_(x) 1.2 Ca 10 present yes yes yes 80.4 80.6 96.0 2-24 20 80.6 80.6 97.0 2-25 50 80.6 80.7 98.0 2-26 60 80.6 80.7 98.0

TABLE 3 Compound Valence Cycle Initial Load Experimental Proportion state requirement retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 rate (%) (%) rate (%) 2-27 SiO_(x) 1.2 Ti 10 present yes yes yes 81.2 81.0 96.0 2-28 20 81.2 81.2 97.0 2-29 50 81.3 81.0 98.0 2-30 60 81.2 81.0 98.0 2-31 SiO_(x) 1.2 Cr 10 present yes yes yes 80.5 80.7 96.0 2-32 20 80.5 80.8 97.0 2-33 50 80.6 80.8 98.0 2-34 60 80.7 80.7 98.0 2-35 SiO_(x) 1.2 Mn 10 present yes yes yes 80.9 80.9 96.0 2-36 20 81.1 80.9 97.0 2-37 50 81.0 80.7 98.0 2-38 60 81.1 80.8 98.0 2-39 SiO_(x) 1.2 Co 10 present yes yes yes 81.0 80.9 96.0 2-40 20 81.0 80.9 97.0 2-41 50 81.1 80.8 98.0 2-42 60 81.1 80.8 98.0 2-43 SiO_(x) 1.2 Ge 10 present yes yes yes 80.8 81.1 97.0 2-44 20 80.6 81.2 97.0 2-45 50 80.7 81.2 98.0 2-46 60 80.7 81.2 98.0 2-47 SiO_(x) 1.2 Zr 10 present yes yes yes 80.8 81.0 96.0 2-48 20 80.6 80.9 97.0 2-49 50 80.6 80.9 98.0 2-50 60 80.6 80.9 98.0

TABLE 4 Compound Valence Cycle Initial Load Experimental Proportion state requirement retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 rate (%) (%) rate (%) 2-51 SiO_(x) 1.2 Mo 10 present yes yes yes 81.2 80.8 97.0 2-52 20 81.1 80.8 97.0 2-53 50 81.2 80.7 98.0 2-54 60 81.2 80.7 98.0 2-55 SiO_(x) 1.2 Ag 10 present yes yes yes 81.0 81.5 96.0 2-56 20 81.1 81.7 96.0 2-57 50 80.9 81.5 97.0 2-58 60 80.9 81.4 98.0 2-59 SiO_(x) 1.2 Sn 5 present yes yes yes 80.5 82.4 97.0 2-60 10 80.5 82.5 97.0 2-61 15 80.5 82.5 97.0 2-62 20 80.6 82.4 97.0 2-63 50 80.3 82.5 98.0 2-64 60 80.2 82.5 98.0 2-65 SiO_(x) 1.2 Ba 10 present yes yes yes 80.4 81.5 96.0 2-66 20 80.5 81.3 96.0 2-67 50 80.5 81.2 97.0 2-68 60 80.4 81.0 98.0 2-69 SiO_(x) 1.2 W 10 present yes yes yes 80.3 82.0 96.0 2-70 20 80.3 82.1 97.0 2-71 50 80.2 82.0 98.0 2-72 60 80.3 81.8 98.0 2-73 SiO_(x) 1.2 Ta 10 present yes yes yes 80.2 82.0 96.0 2-74 20 80.2 82.3 97.0 2-75 50 80.3 82.3 98.0 2-76 60 80.3 82.1 98.0

TABLE 5 Compound Valence Cycle Initial Load Experimental Proportion state requirement retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 rate (%) (%) rate (%) 2-77 SiO_(x) 1.2 Na 10 present yes yes yes 80.6 81.5 96.0 2-78 20 80.6 81.6 96.0 2-79 50 80.8 81.5 97.0 2-80 60 81.0 81.3 98.0 2-81 SiO_(x) 1.2 K 10 present yes yes yes 80.6 81.3 96.0 2-82 20 80.6 81.5 96.0 2-83 50 80.6 81.4 97.0 2-84 60 80.6 81.2 98.0 2-85 SiO_(x) 1.2 Ni + Sn 5 + 5 present yes yes yes 81.6 84.0 97.0 2-86 10 + 10 81.5 84.2 97.0 2-87 25 + 25 81.6 84.1 98.0 2-88 30 + 30 81.6 84.1 98.0

Even when different types, ratios, and combinations of Ml metals were used, high cycle retention rates, high initial efficiency, and high load retention rates were obtained as with the results illustrated in Table 1.

Experimental Examples 3-1 to 3-12

As illustrated in Table 6, secondary batteries were produced by the same procedure as in Experimental Examples 1-1 to 1-8, except that the negative-electrode active material contained Li. Characteristics of each of the resulting secondary batteries were investigated. In this case, in order to perform co-deposition with powdered SiO_(y), additional powdered metal Ml (Li) was used. The negative-electrode active material used here contained Li in an uncharged state.

TABLE 6 Compound Valence Cycle Initial Load Experimental Proportion state requirement retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 rate (%) (%) rate (%) 3-1 SiO_(x) 1.2 Li 1 present yes yes yes 80.6 70.5 97.0 3-2 5 80.7 72.0 98.0 3-3 10 80.6 74.0 98.0 3-4 20 80.6 78.0 98.0 3-5 40 80.9 86.0 98.0 3-6 SiO_(x) 1.2 Li 10 absent yes yes yes 80.6 72.0 98.0 3-7 20 80.6 76.0 98.0 3-8 SiO_(x) 1.2 Ni + Li 5 + 5 present yes yes yes 81.0 85.0 97.0 3-9 10 + 5  81.2 85.5 98.0 3-10 15 + 5  81.4 85.5 98.0 3-11 25 + 10 81.4 87.5 98.0 3-12 30 + 10 81.4 88.0 98.0

Even when Ml contained Li, high cycle retention rates, high initial efficiency, and high load retention rates were obtained. Furthermore, when the negative-electrode active material contained SiMlO (SiLiO), the initial efficiency was further increased.

Experimental Examples 4-1 to 4-8

As illustrated in Table 7, secondary batteries were produced by the same procedure as in Experimental Examples 1-1 to 1-8, except that the atomic ratio x was changed. Characteristics of each of the resulting secondary batteries were investigated. In this case, the oxygen flow rate was adjusted during the melt-solidification of the raw material to control the atomic ratio x.

TABLE 7 Compound Valence Cycle Initial Load Experimental Proportion state requirement retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 rate (%) (%) rate (%) 4-1 SiO_(x) 0 Ni 10 present yes yes yes 65.0 86.0 98.0 4-2 0.2 74.0 84.0 98.0 4-3 0.5 80.0 83.5 97.0 4-4 0.7 80.2 83.0 97.0 4-5 1 80.2 82.5 97.0 4-6 1.4 80.1 80.8 96.0 4-7 1.8 80.0 80.0 95.0 4-8 2 not not not measurable measurable measurable

When the atomic ratio x was 0.5≦x≦1.5, a high cycle retention rate, high initial efficiency, and a high load retention rate were obtained. When the atomic ratio x=2, the discharge capacity was not obtained, thus failing to calculate the cycle retention rate and so forth.

Experimental Example 5-1 to 5-3

As illustrated in Table 8, secondary batteries were produced by the same procedure as in Experimental Examples 1-1 to 1-8, except that the negative-electrode active material had a multilayer structure. Characteristics of each of the resulting secondary batteries were investigated. In this case, when the negative-electrode active material was formed, a step of depositing a material constituting the negative-electrode active material layer was performed twice.

TABLE 8 Compound Valence Compound Cycle Initial Load Experimental Proportion state requirement state Layer retention rate efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 (SiLi0) structure (%) (%) rate (%) 5-1 SiO_(x) 1.2 Ni 15 present yes yes yes absent present 81.6 81.9 97.0 5-2 Ni + Li 15 + 5 present present 81.8 85.5 97.0 5-3 Sn 10 absent present 80.5 82.6 97.0

When the negative-electrode active material had a multilayer structure, the cycle retention rate was increased.

Experimental Examples 6-1 to 6-9

As illustrated in Table 9, secondary batteries were produced by the same procedure as in Experimental Examples 1-1 to 1-8, except that the valence requirements were changed. Characteristics of each of the resulting secondary batteries were investigated.

TABLE 9 Compound Valence Compound Cycle Initial Load Experimental Proportion state requirement state retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 (SiLi0) rate (%) (%) rate (%) 6-1 SiO_(x) 1.2 Ni 15 present no yes yes absent 80.4 80.9 93.0 6-2 Ni + Li 15 + 5 present 80.3 84.5 94.0 6-3 Sn 10 absent 80.6 81.0 93.0 6-4 SiO_(x) 1.2 Ni 15 present yes no yes absent 76.0 81.0 97.0 6-5 Ni + Li 15 + 5 present 78.0 85.0 98.0 6-6 Sn 10 absent 75.0 81.6 97.0 6-7 SiO_(x) 1.2 Ni 15 present yes yes no absent 75.0 82.0 97.0 6-8 Ni + Li 15 + 5 present 76.0 86.0 98.0 6-9 Sn 10 absent 73.0 82.0 97.0

When all of the valence requirements 1 to 3 were satisfied, the cycle retention rate, the initial efficiency, and the load retention rate were increased.

Experimental Examples 7-1 to 7-6)

As illustrated in Table 10, secondary batteries were produced by the same procedure as in Experimental Examples 1-1 to 1-8, except that the median diameter of the negative-electrode active material was changed. Characteristics of each of the resulting secondary batteries were investigated. In this case, the number of grinding operations and so forth were adjusted to control the median diameter.

TABLE 10 Compound Valence Median Cycle Initial Load Experimental Proportion state requirement diameter retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 (nm) rate (%) (%) rate (%) 7-1 SiO_(x) 1.2 Ni 10 present yes yes yes 0.1 80.1 76.0 98.0 7-2 0.3 80.0 78.0 98.0 7-3 1 80.2 80.0 97.0 7-4 10 80.5 81.0 97.0 7-5 20 80.2 80.4 97.0 7-6 30 80.1 78.0 96.0

Even when the median diameter was changed, a high cycle retention rate, high initial efficiency, and a high load retention rate were obtained. In this case, a median diameter of 0.3 μm to 20 μm resulted in a high battery capacity.

Experimental Examples 8-1 to 8-10

As illustrated in Table 11, secondary batteries were produced by the same procedure as in Experimental Examples 1-1 to 1-8, except that a conductive layer was formed on a surface of the negative-electrode active material. Characteristics of each of the resulting secondary batteries were investigated. In this case, a carbon material (graphite) was deposited on the surface of the negative-electrode active material by a powder evaporation method. The average thickness and the average coverage of the conductive layer are described in Table 11.

TABLE 11 Conductive layer Cycle Compound Valence Average Average retention Initial Load Experimental Proportion state requirement thickness coverage rate efficiency retention rate example Composition x M1 (at. %) (SiM10) 1 2 3 Type (nm) (%) (%) (%) (%) 8-1 SiO_(x) 1.2 Ni 10 absent yes yes yes C 100 5 81.2 81.9 97.0 8-2 10 81.5 81.9 98.0 8-3 15 81.6 81.9 98.0 8-4 30 81.8 81.9 98.0 8-5 50 82.0 82.0 98.0 8-6 70 82.5 82.0 98.0 8-7 90 83.0 82.2 98.0 8-8 99 83.5 83.0 98.0 8-9 SiO_(x) 1.2 Ni 10 absent yes yes yes C 200 99 84.1 83.2 98.0 8-10 SiO_(x) 1.2 Ni 10 present yes yes yes C 100 99 80.9 86.0 99.0

57

The formation of the conductive layer resulted in further increases in cycle retention rate, initial efficiency, and load retention rate.

Experimental Examples 9-1 to 9-18

As illustrated in Table 12, secondary batteries were produced by the same procedure as in Experimental Examples 1-1 to 1-8, except that different negative-electrode binders were used. Characteristics of each of the resulting secondary batteries were investigated. In this case, as the negative-electrode binders, polyimide (PI), polyvinylidene fluoride (PVDF), polyamide (PA), polyacrylic acid (PAA), lithium polyacrylate (PAAL), and carbonized polyimide (carbonized PI) were used. In the case where PAA or PAAL was used, a slurry of a negative-electrode mixture was prepared with an aqueous solution containing 17% by volume PAA or PAAL. Hot-pressing was performed to form the negative-electrode active material layers 54B without baking.

TABLE 12 Compound Valence Negative- Cycle Initial Load Experimental Proportion state requirement electrode retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 binder rate (%) (%) rate (%) 9-1 SiO_(x) 1.2 Ni 10 present yes yes yes PI 81.0 81.7 97.0 9-2 20 81.3 81.6 97.0 9-3 50 81.1 81.6 97.0 9-4 SiO_(x) 1.2 Ni 10 present yes yes yes PVDF 80.2 81.1 97.0 9-5 20 80.5 81.2 97.0 9-6 50 80.3 81.0 97.0 9-7 SiO_(x) 1.2 Ni 10 present yes yes yes PA 80.8 81.0 97.0 9-8 20 80.9 81.2 97.0 9-9 50 80.6 81.0 97.0 9-10 SiO_(x) 1.2 Ni 10 present yes yes yes PAA 80.9 81.3 97.0 9-11 20 80.6 81.2 97.0 9-12 50 80.8 81.2 97.0 9-13 SiO_(x) 1.2 Ni 10 present yes yes yes PAAL 81.0 82.0 97.0 9-14 20 81.1 82.1 97.0 9-15 50 81.0 82.0 97.0 9-16 SiO_(x) 1.2 Ni 10 present yes yes yes carbonized 81.2 81.6 97.0 9-17 20 PI 81.5 81.7 97.0 9-18 50 81.4 81.6 97.0

Even when different negative-electrode binders were used, high cycle retention rates, high initial efficiency, and high load retention rates were obtained.

Experimental Examples 10-1 to 10-12

As illustrated in Table 13, secondary batteries were produced by the same procedure as in Experimental Examples 1-1 to 1-8, except that different positive-electrode active materials were used. Characteristics of each of the resulting secondary batteries were investigated.

TABLE 13 Compound Valence Cycle Initial Load Experimental Proportion state requirement Positive electrode active retention efficiency retention example Composition x M1 (at. %) (SiM10) 1 2 3 material rate (%) (%) rate (%) 10-1 SiO_(x) 1.2 Ni 10 present yes yes yes LiNi_(0.70)Co_(0.25)Al_(0.05)O₂ 80.6 83.5 97.0 10-2 LiNi_(0.79)Co_(0.14)Al_(0.07)O₂ 80.8 83.6 97.0 10-3 LiNi_(0.70)Co_(0.25)Mg_(0.05)O₂ 81.1 83.7 97.0 10-4 LiNi_(0.70)Co_(0.25)Fe_(0.05)O₂ 81.0 83.6 97.0 10-5 LiNiO₂ 81.1 83.7 97.0 10-6 LiNi_(0.33)Co_(0.33)Mn_(0.33)O₂ 81.0 83.6 97.0 10-7 LiNi_(0.13)Co_(0.60)Mn_(0.27)O₂ 81.2 83.7 97.0 10-8 Li_(1.13)[Ni_(0.22)Co_(0.18)Mn_(0.60)]_(0.87)O₂ 81.5 83.5 97.0 10-9 Li_(1.13)[Ni_(0.20)Co_(0.20)Mn_(0.60)]_(0.87)O₂ 81.1 83.6 97.0 10-10 Li_(1.13)[Ni_(0.18)Co_(0.22)Mn_(0.60)]_(0.87)O₂ 81.0 83.6 97.0 10-11 Li_(1.13)[Ni_(0.25)Co_(0.25)Mn_(0.50)]_(0.87)O₂ 81.4 83.5 97.0 10-12 Li₂Ni_(0.40)Cu_(0.60)O₂ 81.2 83.7 97.0

Even when different positive-electrode active materials were used, high cycle retention rates, high initial efficiency, and high load retention rates were obtained.

The results illustrated in Tables 1 to 13 demonstrated that in the case where the negative-electrode active material contained, as constituent elements, Si, O, and element Ml, such as Li, and where the atomic ratio x of O to Si was 0.5≦x≦1.8, high cycle characteristics, high initial charge-discharge characteristics, and high load characteristics were obtained.

While the present application has been described above with reference to the embodiments and examples, the present application is not limited to these embodiments and examples. Various modifications may be made. For example, while the capacity of the negative electrode has been represented on the basis of the occlusion and release of lithium ions in the above-described embodiments, the present application is not necessarily limited thereto. The present application is also applicable to the case where the capacity of a negative electrode includes a capacity on the basis of the occlusion and release of lithium ions and a capacity on the basis of the deposition and dissolution of metallic Li, and is expressed as the sum of the capacities. In this case, as the negative-electrode active material, a negative-electrode material capable of occluding and releasing lithium ions is used, and the chargeable capacity of the negative-electrode material is set to be higher than the discharge capacity of the positive electrode.

While the case where the battery has a prismatic shape, a cylindrical shape, or a laminated-film shape and where the battery element has a spirally wound structure has been described above, the present application is not necessarily limited thereto. The present application is also applicable to a battery having a prismatic shape, a button shape, or the like, or to a battery element having a laminated structure.

It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. 

1. A lithium-ion secondary battery comprising: a positive electrode; a negative electrode containing an active material; and an electrolytic solution, wherein the active material contains, as constituent elements, Si, O, and at least one element Ml selected from Li, C, Mg, Al, Ca, Ti, Cr, Mn, Fe, Co, Ni, Cu, Ge, Zr, Mo, Ag, Sn, Ba, W, Ta, Na, and K, and the atomic ratio x (O/Si) of O to Si is 0.5≦x≦1.8.
 2. The lithium-ion secondary battery according to claim 1, wherein the ratio of Ml to Si and O, i.e., Ml/(Si+O), is 50 atomic percent or less.
 3. The lithium-ion secondary battery according to claim 1, wherein at least one of the atoms of Ml is bonded to at least one of Si and O.
 4. The lithium-ion secondary battery according to claim 3, wherein the active material of the negative electrode contains a compound of Si, O, and Ml.
 5. The lithium-ion secondary battery according to claim 1, wherein at least one of the atoms of Si is bonded to at least one of the atoms of O to form a compound, and wherein the bonding states (valence states) of Si atoms bonded to O atoms include zero valence (Si⁰⁺), monovalence (Si¹⁺), divalence (Si²⁺), trivalence (Si³⁺), and tetravalence (Si⁴⁺).
 6. The lithium-ion secondary battery according to claim 5, wherein the proportions (atomic ratios) of the bonding states of Si atoms bonded to O atoms satisfy the relationships Si⁴⁺<Si⁰⁺+Si¹⁺+Si²⁺+Si³⁺, Si⁴⁺>Si⁰⁺, Si⁴⁺≧Si¹⁺, and Si⁴⁺≧Si²⁺, and wherein the proportion of Si¹⁺ is less than 10 atomic percent.
 7. The lithium-ion secondary battery according to claim 1, wherein the active material contains Li as a constituent element in an uncharged state.
 8. The lithium-ion secondary battery according to claim 7, wherein the active material contains a compound of Si, Li, and O.
 9. The lithium-ion secondary battery according to claim 1, wherein the active material has a median diameter of 0.3 μm to 20 μm.
 10. The lithium-ion secondary battery according to claim 1, wherein the negative electrode includes a conductive layer arranged on at least part of a surface of the active material, the conductive layer having a lower electrical resistance than the active material.
 11. The lithium-ion secondary battery according to claim 10, wherein the conductive layer contains a carbon material.
 12. The lithium-ion secondary battery according to claim 1, wherein the negative electrode contains a binder, wherein the binder contains at least one selected from polyimide, polyamide-imide, polyamide, polyvinylidene fluoride, polyacrylic acid, lithium polyacrylate, sodium polyacrylate, polymaleic acid, copolymers thereof, carboxymethyl cellulose, styrene-butadiene rubber, and polyvinyl alcohol.
 13. A negative electrode for a lithium-ion secondary battery, the negative electrode comprising: an active material, wherein the active material contains, as constituent elements, Si, O, and at least one element Ml selected from Li, C, Mg, Al, Ca, Ti, Cr, Mn, Fe, Co, Ni, Cu, Ge, Zr, Mo, Ag, Sn, Ba, W, Ta, Na, and K, and the atomic ratio x (O/Si) of O to Si is 0.5≦x≦1.8.
 14. A battery pack comprising: the lithium-ion secondary battery according to claim 1; a controller configured to control the usage state of the lithium-ion secondary battery; and a switching unit configured to switch the usage state of the lithium-ion secondary battery in response to an instruction from the controller.
 15. An electric vehicle comprising: the lithium-ion secondary battery according to claim 1; a conversion unit configured to convert power from the lithium-ion secondary battery into a driving force; a driven unit configured to be driven in response to the driving force; and a controller configured to control the usage state of the lithium-ion secondary battery.
 16. A power storage system comprising: the lithium-ion secondary battery according to claim 1; one or two or more electrical devices; and a controller configured to control the power supply from the lithium-ion secondary battery to the electrical devices.
 17. An electric tool comprising: the lithium-ion secondary battery according to claim 1; and a moving part powered by the lithium-ion secondary battery.
 18. An electronic device comprising: the lithium-ion secondary battery according to claim 1, wherein the electronic device is powered by the lithium-ion secondary battery. 